ANHALTISCHE

ELEKTROMOTORENWERK
DESSAU GMBH

KAD 30240/E
Edition 01/2014

Read through before initial operation and store carefully for later reference!

Mounting, operating
and maintenance instructions
for series SE and SEH
brushless three-phase synchronous generators

AEM
Anhaltische Elektromotorenwerk Dessau GmbH
Daheimstr. 18
D - 06842 Dessau - Roßlau

After-sales service
Tel.: +49 (0) 340 203 304
Fax: +49 (0) 340 203 311

e-mail: [email protected]
homepage: www.aemdessau.de
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ELEKTROMOTORENWERK
DESSAU GMBH

General safety instructions

Notes for use

The notes used in the operating instructions have the following significance:

Danger!
Is used for activities that may cause considerable personal or material damage.
Please read and observe these notes carefully and act particularly cautiously in these
cases. Make other users aware of these notes concerning work safety.

ATTENTION! Concerns the observation of regulations, notes or the correct sequence of working
steps to avoid damaging or destroying the generator, its parts and/or parts of the
equipment.

NOTE General type of notes

______________________________________________________________________________________

General safety instructions

Electrical generators are designed for use in commercial installations. During operation, these genera-
tors have dangerous rotating and non-insulated voltage-carrying parts. Serious personal and material dam-
age may be caused by improper use, impermissible removal of covers and protective installations, wrong
handling and insufficient maintenance.

All work to be carried out on electrical generators such as assembly, connection or maintenance must
only be carried out while the system carries no voltage and is out of operation. Protect the system
against unintended reactivation.

These generators must only be transported, put up, connected, put into operation, maintenanced and operated
by specialized staff being trained to observe the relevant safety and installation regulations. All processes must
be checked by responsible specialized staff. These specialized staff must have been authorized for their activi-
ties by the security system officer (for specialized staff regulations see DIN EN 50110-1 / DIN IEC 60364).

Operation by non-qualified staff is prohibited!

The person responsible for the installation must make sure

• to have safety and operating instructions available and observing them;
• to have all safety installations and personal safety equipment available;
• that safety installations and personal safety equipment are used;
• regulatory maintenance work is carried out;
• the maintenance staff are immediately informed or the generator stopped if abnormal voltages, in-
creased temperatures, oscillations, noises etc. occur so that causes can be determined and damages
avoided.

The manufacturer's liability is only maintained if the operating instructions are being observed at any
time!

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Table of contents
1 Description................................................................................................................................................... 6
1.1 Regulations and classifications ............................................................................................................ 6
1.2 Design .................................................................................................................................................. 6
1.3 Bearings ............................................................................................................................................... 6
1.4 Cooling system ..................................................................................................................................... 6
1.5 Exciter system ...................................................................................................................................... 6
1.6 Voltage regulator .................................................................................................................................. 7
2 Behaviour during operation and notes on use ............................................................................................ 8
2.1 Excitation, de-excitation ....................................................................................................................... 8
2.2 Setting range for voltages, set-point adjuster ...................................................................................... 8
2.3 Voltage behaviour ................................................................................................................................ 8
2.4 Radio interference suppression ........................................................................................................... 9
2.5 Operational behaviour .......................................................................................................................... 9
2.5.1 Overload capability ....................................................................................................................... 9
2.5.2 Operation with different temperatures of the cooling agent .......................................................... 9
2.5.3 Operation at power factors p.f. < 0.8 ............................................................................................ 9
2.5.4 Underspeed .................................................................................................................................. 9
2.6 Short-circuit behaviour ......................................................................................................................... 9
2.7 Single operation ................................................................................................................................... 9
2.8 Parallel operation ................................................................................................................................. 9
2.8.1 Practical applications .................................................................................................................... 9
2.8.2 Neutral earthing current .............................................................................................................. 10
2.8.3 Synchronisation .......................................................................................................................... 10
2.8.4 Parallel operation with static ....................................................................................................... 11
2.8.5 Parallel operation with compensating line .................................................................................. 11
2.8.6 Parallel network operation with static ......................................................................................... 12
2.9 Emergency operation without regulator ............................................................................................. 12
3 Transport ................................................................................................................................................... 12
3.1 Check after delivery ........................................................................................................................... 12
3.2 Transport locking device .................................................................................................................... 12
3.2.1 Cylindrical roller bearings............................................................................................................ 13
3.2.2 Slide bearings .............................................................................................................................13
3.2.3 Single bearing - and vertical generators ..................................................................................... 13
4 Mounting .................................................................................................................................................... 13
4.1 Installation and connection................................................................................................................. 13
4.2 Electrical connection .......................................................................................................................... 14
4.3 Terminal box and connections ........................................................................................................... 15
4.4 Direction of rotation ............................................................................................................................ 15
5 First start up............................................................................................................................................... 16
5.1 Electrical check .................................................................................................................................. 16
5.2 Measuring of the insulation resistance ............................................................................................... 16
5.3 Mechanical check ............................................................................................................................... 17
6 Maintenance .............................................................................................................................................. 17
6.1 General information ............................................................................................................................ 17
6.1.1 Insulation value and standstill heater.......................................................................................... 17
6.1.2 Maintenance work at the drive .................................................................................................... 17
6.1.3 Preventive maintenance ............................................................................................................. 17
6.2 Lubrication and maintenance instructions for antifriction bearings .................................................... 18
6.2.1 Lubricant information .................................................................................................................. 18
6.2.2 Bearings with relubrication device .............................................................................................. 18
6.2.3 Removing used grease ............................................................................................................... 18
6.2.4 Bearings without relubrication device ......................................................................................... 18
6.2.5 Maintenance instructions ............................................................................................................ 19
6.3 Lubricating and maintenance instructions for slide bearings ............................................................. 19
6.3.1 Oil renewal .................................................................................................................................. 19
6.3.2 Inspection of bearings ................................................................................................................. 19
6.4 Cleaning ............................................................................................................................................. 19
6.5 Drying the winding ..............................................................................................................................19
6.6 Assembly of bearings ......................................................................................................................... 20
7 Supplementary installations ...................................................................................................................... 21

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7.1 Temperature monitoring ..................................................................................................................... 21

7.1.1 Thermal winding protection ......................................................................................................... 21
7.1.2 Thermal bearing monitoring ........................................................................................................ 21
7.1.3 Thermal cooling air monitoring.................................................................................................... 21
7.1.4 PTC resistor temperature probe (PTC thermistors in acc. to DIN 44081) .................................. 21
7.1.5 Platinum measuring resistors (Pt100 sensors in acc. to DIN EN 60751) ................................... 21
7.1.6 Silicon sensors (KTY sensors) .................................................................................................... 22
7.1.7 Note on repairs and retrofit packages......................................................................................... 22
7.2 Standstill heater ................................................................................................................................. 22
7.3 Air filter ............................................................................................................................................... 23
7.4 Additional protection and measuring transformers ............................................................................ 23
8 Storage instructions ................................................................................................................................... 23
9 Troubleshooting ......................................................................................................................................... 23
9.1 Thermal and mechanical problems .................................................................................................... 23
9.2 Voltage problems ............................................................................................................................... 24
9.3 Checking and replacing the rectifier diode ......................................................................................... 24
9.4 Testing varistors ................................................................................................................................. 24
9.5 Replacing the regulator ...................................................................................................................... 24
9.6 Problems overview .............................................................................................................................25
10 Spare parts ............................................................................................................................................ 27

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View of generator N side

7.1

11 R R31
6.1 7
9.2
8
9

6
S1
10
5

Description of view

5 Rotating rectifier 9.2 Regulator potentiometer

6 Choke coil 10 Radio interference suppression capacitor
6.1 Choke coil terminal strip 11 Static current transformer
7 Current transformers K Terminal strip X100:1, X100:2, ...
7.1 Current transformers terminal strip R Terminal strip regulator
8 Stationary rectifier R31 Step-down resistor
9 Voltage regulator S1 Voltage surge protector

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1 Description
1.1 Regulations and classifications
The generators are made in compliance with the regulations of DIN EN 60034 / VDE 0530 (Rotating electri-
cal machines), all applicable IEC recommendations and the harmonized EG-standards and order-specific
customized classifications – specially acc. to the most important marine classifications associations.

1.2 Design
The generators consist of
• one inner-pole main machine with salient pole or non-salient pole rotor
• one external-pole exciter with rotating rectifiers for transmission of the exciting power and
• one exciter device with electronic voltage regulator.
Generator, exciter and all other components required for excitation and regulation are designed to form one
compact unit. The casing consists of the stator, the end shields and a hood to serve as a cover for the exciter
unit on the N side. In the standard design, the terminal box is at the top and can be turned by 180°. Both
terminal box and casing have specially designated earth connection points.

1.3 Bearings
The system is equipped with spring-loaded deep groove ball bearings (standard mode), cylindrical roller
bearings or plain bearings as defined in the order.
In case of increased loads on the bearings, a cylindrical roller bearing is installed on the D side while a deep
groove ball bearing is on the N side to serve as counter bearing or, if necessary, a double bearing made up
of a cylindrical roller bearing and a deep groove ball bearing.
Generators in vertical design have an angular contact ball bearing to serve as counter bearing. All bearings
are dust-proof, are permanently lubricated up to shaft centre height 315 mm and are provided with relubrica-
tion devices with grease quantity regulation on both the D and the N side as from shaft centre height
400 mm. Relubrication devices for shaft centre height 315 mm are subject to special arrangements.
NOTE For bearing configuration observe Data sheet “Bearings” and lubrication- and maintenance
instructions observe section 6.2.

1.4 Cooling system

The generators are self-ventilated with the air inlet being axially on the N side. The air outlet is on the D side
through a radial ventilator. In some cases, ventilators depending on the direction of rotation are used to
minimize the air noise.
NOTE Observe section 4.4 "Direction of rotation"!
Generators with higher protection systems (> IP 23) are equipped with filters or pipe connection on their D
and N sides (self-ventilation in accordance with IC 31, external ventilation in accordance with IC 36) or with
air-to-water or air-to-air type heat exchangers (IC 81W7 or IC 81A7).

1.5 Exciter system

Design
The exciter system consists essentially of the following assembly groups:
• Choke [6]
• Current transformer [7]
• Stationary rectifier stack [8] with step-down resistor R31
• Electronic voltage regulator [9]
All units are installed on a panel on the N side end shield. Exciter system and rotating rectifier stack can be
accessed by taking off the hood and opening the clamps or the screw connection (for instructions on how to
take off the hood observe section 6.6).
For generator voltages higher 1 kV, an additional transformer with a secondary voltage of 400 V [14] built in
to separate the AVR from the high-voltage side. The AVR is in a separate connection box. The exciter unit is
protected against unauthorized changes.
Working principle
The remanence voltage produced in the stator winding [1] of the generator causes a small current to flow
through the stator winding [4] of the exciter via choke [6] and rectifier stack [8] thus setting off self-excitation.
The choke [6] limits the exciter current of the exciter. The exact value depends on the air gap between core
and yoke of the choke. The required air gap is adjusted by adding insulating material.
NOTE For generator voltages higher 1 kV, an additional auxiliary winding is built in into the stator.
The voltage of this auxiliary winding serve as remanence voltage and supply the choke.

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The load current flows through the current transformer [7]. When load is put on the generator, the secon-
dary current of the current transformer [7] is added to the choke current. After rectification in the stationary
rectifier stack [8] – a six-pulse bridge circuit –, this alternating exciter current flows to the stator winding [4] of
the exciter.
In order to protect the diodes against voltage peaks, both the stationary rectifier stack [8] and the rotating
rectifier stack [5] are equipped with varistors [S1], [S2].
Choke current and secondary current of the current transformer are adjusted such as to permanently main-
tain a generator voltage of approx. 10 % above the rated generator voltage while the generator rotates at its
rated speed and the voltage regulator is disconnected.
Every time the rated generator voltage is exceeded, the voltage regulator (AVR) [9] periodically switches on
step-down resistor R31 that is located in parallel to the stator winding of the exciter [4]. This ensures that the
teminal voltage of the generator is kept at the value set by the set-point adjuster.
NOTE The chosen tappings of the winding to choke and current transformer have been optimally
adjusted to the generator in the manufacturer's test shop. You should therefore always con-
tact the manufacturer prior to making any changes.

1.6 Voltage regulator

Design
The voltage regulator is located in a sealed casing protected against dust and dirt. The casing contains the
potentiometers for setting the various regulator functions.
The potentiometers are equipped with a self-locking multi-speed mandrel drive that is secured against over-
speed by a slide clutch. The setting range is approximately ± 12 turns.
The regulators are equipped with smoothing capacitor Ck and varistor to stabilize and filter the exiter energy.
The basic model of the regulator has the ability to regulate the voltage and to generate static for parallel op-
eration. Regulator types with additional functions such as power factor regulation or frequency-dependent
voltage regulation may be employed also.

NOTE: Check the regulator documentation supplied with the machine regarding operation and ad-
justment of the regulator!

NOTE If the generator voltage deviates from the permissible operating voltage range of the regula-
tor, the regulator will be either connected to tappings of the stator winding or special measur-
ing transformers. For generator voltages higher 1 kV the AVR is connected to a special
measuring transformeras well as decoupled from the operating voltage of the generator.

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2 Behaviour during operation and notes on use

Danger!
Only trained specialized staff are allowed to change settings using a suitable tool.
Observe during all setting and other work to be carried out on exciter and regulator
that all components supply voltage potential.

2.1 Excitation, de-excitation

Excitation
Self-excitation is provided by the remanence voltage.

Danger!
Measure the generator voltage during the excitation process. Remove the external
voltage source immediately, when the generator voltage rises. Use a diode to be pro-
tected against Danger of reverse current!

If self-excitation of the generator does not work, excitation can be induced by briefly applying an external
voltage (6 or 12 V battery) to terminals X100:3/+ (battery plus), X100:4/- (battery minus) in the terminal box
of the generator (figure 1).

Figure 1: Generator excitation and de-excitation circuit

De-excitation

Danger!
After de-excitation and while the drive is running, there is a residual voltage of up to
10 % of the network voltage on the generator terminals. Special notice for generators
with voltage more than 1 kV.

Use a contactor or suitable switch to produce a short-circuit between terminals X100:3/+ and X100:4/-.
Current load on the contacts is < 10 A (figure 3).

2.2 Setting range for voltages, set-point adjuster

The terminal voltage may be adjusted on the regulator within a range of approx. ± 5 % up to ± 10 %of the
rated value depending on the type of regulator. Additionally, it is possible to adjust the set point externally.
The adjustment ranges, connection types and interface descriptions depend on the type of regulator. They
are specified in the regulator documentation supplied with the individual machine which has to be read
through carefully before starting operation.

2.3 Voltage behaviour

Static voltage behaviour
The voltage regulator maintains the set terminal voltage between no-load and rated current for power factors in
a range of p.f. = 0.5 (over-excited) to 1.0 with a tolerance value of less than ± 1 %. This constant voltage works
for operation without static device. Valid speed increases of the generator drive are up to 105 % of the rated
speed between rated output and no-load operation.

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Dynamic voltage behaviour

Switching-on load causes a voltage drop which is corrected within a certain response time. Voltage drop as
well as response time are dependent on power, number of poles of the generator and dimensioning of the
machine. The voltage drop when switching-on rated load with a power factor of p.f. = 0.8 may be limited to
approx. 12 -15 % with a response time of 0.3 – 0.5s. Greater additional loads are possible. However, in this
case the voltage may drop by up to approx. 30 %. Please contact the manufacturer for further information.
Voltage stability
The regulator is delivered with optimal settings for static and dynamic voltage behaviour. If the output voltage
oscillates, the regulating behaviour may be adjusted. This procedure is described in the supplied regulator
documentation.

2.4 Radio interference suppression

Radio interference suppression voltage and interference resistence correspond to DIN EN 61000-6-4 and
DIN EN 55016-1, -2 and -4 unless other arrangements were made with the manufacturer.

2.5 Operational behaviour

2.5.1 Overload capability
Current overload of generator is permissible 10 % for 1 hour (once within 6 hours) or 50 % for 2 minutes at
p.f. = 0.5. Brief overloads at motor starting operations are permissible. During overload conditions, the volt-
age tolerance of ± 1 % is no longer valid.
2.5.2 Operation with different temperatures of the cooling agent
The rated output stated on the type label is only valid in conjunction with the stated temperature of the cool-
ing agent. For other temperatures, the following output changes apply:

T / °C 30 35 40 45 50 55 60
PS / PN 1.06 1.03 1.00 0.96 0.92 0.88 0.84

ATTENTION! Operation in ambient temperatures above 60 °C require manufacturer approval.

2.5.3 Operation at power factors p.f. < 0.8
For power factors p.f. < 0.8, the apparent generator power must be reduced in relation to the power factor.

p.f. 0.7 0.6 0.5 0.4 0.0

PS / PN 0.94 0.89 0.85 0.82 0.80

2.5.4 Underspeed
Particular protection of the generator, the exciter or the regulator against underspeed of the generator drive
(e.g. during warm-up) is not required. Voltage is maintained constant down to speeds of approx. 90 % of the
rated speed. Below this value, the voltage is reduced approximately proportionally to the speed so that every
speed is admissible in no-load without time limitation.

2.6 Short-circuit behaviour

The current surge (15 - 21 x IN) occurring during short-circuit conditions goes down to the sustained short-
circuit current after about 60 to 100 ms. Stable sustained short-circuit current of not less than three times the
rated generator current is guaranteed for up to 5 sec. Please refer to the data sheet of the generator for all
other values. The sustained short-circuit current on one pole is approx. 5 - 6 x IN.

2.7 Single operation

In single operation mode, the static current transformer can be deactivated by putting in a jumper between
terminals 4 - 5 (figure 2). This guarantees optimally constant voltage level for the generator.
NOTE Single operation is possible without limitations if there is no jumper between 4 and 5 (parallel
operation circuit). In this case, voltage tolerances are determined by the static setting and
may be above 2 %.

2.8 Parallel operation

2.8.1 Practical applications
Brushless AEM - generators are designed for parallel operation. They are equipped with damper winding,
connection for compensator circuit, static device and voltage set-point adjuster.
The following variations of parallel operation are possible:

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• Parallel operation with static with other generators as long as these provide parallel operation features
and if practically the same static voltage curves with falling characteristics can be set for all generators;
• Parallel operation with compensator circuits of generators of the same type;
• Parallel network operation either with non-regulated power factor in static mode or with regulated
power factor according to regulator type with power factor regulation.
For parallel operation of several generators, reactive power distribution as well as current and power output
variations must be within the range of applicable regulations. Prerequisites for this kind of operation are that
generator drives, and their speed governors in particular, are designed correspondingly providing the same
P range (speed drop between no-load and full load operation) or that an active power distribution propor-
tional to the power output is ensured by an automatic active power distribution installation.
Measure Effect during Main effect during
single operation parallel operation
Voltage set point of the gen- Over-excited: generator supplies more
Ï Generator voltage Ï
erator reactive power
Under-excited: generator supplies
Generator statics Ð ----------- less reactive power
Voltage set point of the gen- Generator voltage Ð Over-excited: generator supplies less
Ð
erator reactive power
Under-excited: generator supplies
Generator statics Ï ----------- more reactive power
Rated speed of the drive Ï Frequency Ï Generator supplies more active power
Rated speed of the drive Ð Frequency Ð Generator supplies less active power

NOTE Wrong distribution of active power (kW indicator not proportional to power output) is always
caused by the speed regulation of the generator drives.

Wrong distribution of reactive current (kW distribution o.k., different current distribution) is
caused by the voltage and static settings of the regulator.
2.8.2 Neutral earthing current
In parallel operation there are not neutral-earthing currents normally while using of same generator types of
one manufacturer.
Connecting the generator star point to the star points of generators of another type or to the network earthed
neutral can cause compensation currents of mainly three times the network frequency to flow in the neutral
earth conductor that have been caused by different voltage curve lines of generators and mains network.
Neutral currents of up to 40 % of the rated current are admissible unless other values have been defined.
Reducing the neutral current can be achieved by inserting a special type of choke coil in the network
switchboard (please contact the manufacturer).
2.8.3 Synchronisation
The generators can be synchronized by manual synchronisation, automatically quick synchronisation or start
up synchronisation (please contact the manufacturer).
The following conditions must be observed for synchronisation processes:
• almost identical frequency of the two voltage systems Δf ≤ 0.2 Hz
• almost identical terminal voltage of the generator and mains network, admissible difference < 6 %
• identical phase sequence of the two voltage systems
• closing of switching contacts at a phase angle of < 15 degrees in relation to the zero crossover of the dif-
ference voltage of the two voltage systems.

ATTENTION! Wrong synchronisation causes extremely high electrical and mechanical loads on the
generator which must be avoided under all circumstances.
Manual synchronisation
Use the set-point adjuster to set the generator voltage to the network voltage. After setting smallest fre-
quency and phase differences possible by means of a synchronoscope, the generator can be switched on.
To avoid the occurrence of inverse power after switching on the generator, the generator frequency should
be about 0.2 Hz above the network frequency.

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Quick synchronisation
Use an electronic synchronisation device to adjust the system to smallest possible voltage, frequency and
phase differences automatically. The generator will be switched on considering that time element (switch) is
in zero crossover range of the difference voltage.
2.8.4 Parallel operation with static
ATTENTION! Check whether the jumper between terminals 4 and 5 of the regulator have been re-
moved.
Depending on current and power factor, the generator voltage characteristics show a decline. The voltage drop
can be set on the regulator (max. 8 % at p.f. = 0). The manufacturer sets the static to approx. 2 % (in relation to
no-load voltage) at rated current and a power factor of p.f. = 0.8. Constant voltage during parallel operation de-
pends on the static setting. If static setting and static voltage characteristics are nearly the same, the reactive
power (in relation to the rated power of the corresponding generator) is distributed proportionally.
ATTENTION! Make sure to do a generator adjustment before starting operation.
Only specialized staff must do these steps.
Check whether all drives have the same percentage value for speed drop between no-
load speed and full speed while in single operation.
Use the set-point adjuster to adjust the equal values of no-load voltages (±1 V) at all
generators. For this setting please use the same meter.
Put rated power at rated power factor on the generators in single operation if possible
and check whether an almost identical voltage drop can be observed for all generators.
If you find larger differences, the static potentiometer must be readjusted. Static values of 2 – 3 % at rated
power and rated power factor are sufficient for stable parallel operation. This test must not be made with just
using active power as this renders the static inefficient.
NOTE Proceed as follows to make a supplementary test if only active power operation is possible
when changing the setting:
1. Connect the blue cable from phase U to W and the brown cable from phase V to
phase U on the choke terminal strip [6.1].
2. Put load on the generators.
3. The voltage drop corresponds to static setting at p.f. = 0.5 and normal switching condi-
tions.
4. While corrections of the static adjustment using the equivalent circuit is to be noted that
the static adjustment is made with p.f. = 0.5. The static adjustment will be accordingly
smaller with p.f. = 0.8 therefore.
5. Reconnect all devices after the setup procedure.

Figure 2: Terminal connection for static setting at active power

2.8.5 Parallel operation with compensating line
Generators with the same exciter voltage can work in parallel if there is a compensating line. The generators
are running in this case without static. The voltage is constant for all load. For special information please
consult the manufacturer.

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2.8.6 Parallel network operation with static

A prerequisite for parallel operation of a generator device in a fixed network is that overload conditions in
varying network situations are avoided. On the active load side this is ensured by a speed regulator or an
electronic load distribution. On the reactive load side, this condition must be ensured by implementing a load-
dependent modification of the internal generator voltage. This generator voltage adjustment can be realized
either by the static device or by a regulation that depends on the power factor (p.f.-regulation).

NOTE For synchronisation processes the generator voltage have to be approx. 1 % higher than the
network voltage is.
The static device lowers the generator voltage if the reactive power increases. Greater static causes small
current changes if the network voltage changes. We recommend setting the no load voltage higher than the
highest network voltage occurring at the feeding point to avoid reactive current absorption by the generator
from the network.
ATTENTION! Observe the neutral earthing current (section 2.8.2) and synchronisation conditions
(section 2.8.3).

2.9 Emergency operation without regulator

If the voltage regulator is defective and if no supplementary regulator is available, it is possible to go into
emergency mode. To do so, deactivate the regulator (see Point emergency mode in the regulator documen-
tation)
ATTENTION! Attach and insulate cable ends.
Connect an adjustable resistor of approx. 100 Ω and a load current of approx. 2 A to terminals X100:3,
X100:4 in the generator terminal box.

Danger!
The resistor is under network potential and must therefore be protected against touch-
ing.

The resistor can be used to set the rated generator voltage in the no-load of generator.
The voltage can be kept in the required range by readjustment under load. The voltage tolerance value is
approx. –5 % without readjustment.

3 Transport
ATTENTION! Only use suitable attachment devices (ring bolts, eye bolts) for transportation. The at-
tachment elements that are part of the generator are only made to carry the genera-
tor's own weight.
Check whether screw-type eye bolts are firmly screwed in.
It is not allowed to sling parts of the transport gear around shaft ends, pillow blocks,
sleeves, hoods or similar elements as this could cause considerable damage.
If a generator or unit is transported on its base plate you must use the attachment de-
vices provided in the base plate. Units that must not be transported in one piece are
marked by a corresponding notice on the base plate.
NOTE When transporting parts of disassembled generators ropes for lifting armatures should not
be slung around the shafts bearing site. If no other way of transporting the element is possi-
ble, the shaft must be sufficiently protected.

3.1 Check after delivery

Check the generator for any damages that might have occurred during transportation.
Transport company and manufacturer must be informed immediately of any transport damages.

3.2 Transport locking device

To avoid transport damages to bearings the armature of generators with cylindrical roller bearings is
equipped with a transport locking device. This must only be removed when commissioning the generator and
reused if the generator is transported again. Generators with spring-loaded groove ball bearings do not need
transport protection.
ATTENTION! Remove the transport locking device before putting the generator into operation for
the first time.

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3.2.1 Cylindrical roller bearings

Refer to the figure 3 or the information given inside the terminal
box to learn about how to remove the transport locking device.
Generators with transport locking devices are marked by a corre-
sponding sign. Transport locking device is realized by two fixing
1 screws. To remove it unscrew both hexagonal screws M 12 x 60
[1] by approx.
2 8 – 10 mm and secure against unintended screwing-in by attach-
ing the counter nuts [2].
After removing the transport locking devices, you must race the
generator manually for the control.

Figure 3: Schematic representation of the transport locking

device

3.2.2 Slide bearings

The structure and the function of the transport locking device have to be taking from "data sheet - slide bearings".
3.2.3 Single bearing - and vertical generators
The transport locking device for this generators is described in a special mounting instruction (observe the
order-specific appendix). Pay attention to absolutely!

4 Mounting

Danger!
Observe general security information (see page 2)!

4.1 Installation and connection

Installation conditions
• The generator was designed for temperatures of the cooling agent between –25 °C and + 40 °C and a
mounting location up to a height of 1000 m. Any other information on the performance label must be ob-
served.
• Never install generators labelled as IP 23 degree of protection outdoor. The degree of protection of the
generator must match the local conditions at the point of installation.
• Make sure to let the cooling air get in trough the air inlets and out again through the air outlets without
obstructions or being sucked back in.
• If you are working with external air cooling, make sure to provide the air quantity indicated on the per-
formance label.
• Install the generator on a low-vibration foundation. Avoid tension due to fixing the screws on uneven sur-
faces. Observe the prescribed tightening torques when tightening the foot screws! (Observe the table be-
low.)

M16 M18 M20 M22 M24 M27 M30 M33 M36

Coefficient of
Tightening torques [Nm]
friction
μ = 0,10
180 259 363 495 625 915 1246 1679 2164
(lubricated)
μ = 0,14
230 329 464 634 798 1176 1597 2161 2778
(not lubricated)

• Use taring screws for aligning the generator. The final installation position is to be fixed by sheet metal
put underneath the generator. Bolt the generator up if necessary (holes are drilled into place already).
• When assembling generators that come to you in several pieces, you have to make sure only to use
parts that have been marked as belonging together.
• The generator must only be assembled and operated according to design (see rating plate).
• Always observe the connection conditions for water quantity, pressure and temperature at the inlet given
in the data sheet for water coolers (see appendix).

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• If you are working with a pipe connection with self-ventilation, the pressure drop indicated by the manu-
facturer must in no case be exceeded due to length and layout of piping.
• Make sure to keep sufficient distance to walkways and operating stands as the temperatures of exhaust
air or surface can be up to 80 °C.
ATTENTION! Provide information signs or protective railing.
Coupling
The generator and bearings have been carefully mounted, aligned and completely tested by the manufacturer.
NOTE The rotor is dynamically balanced. The balancing state is marked in accordance with DIN
ISO 8821 at the D-side shaft-end.
Coupling of generators in two-bearing design to the drive unit should be realized by an elastic clutch.
Coupling of generators in single-bearing design: Observe the special documentations in appendix!
Pay attention to absolutely!
Putting on couplings or pulleys
It is not necessary to remove the corrosion protection at the shaft ends during installation.
ATTENTION! Make sure to use a mounting device for mounting couplings or pulleys.
A suitable means for this is the centring drill hole in the shaft end. When putting in the clutch you have to
make sure that the shaft of the drive mechanism and the shaft of the machine to be driven are perfectly
aligned. Misalignment must be not greater than 0.05 mm. To avoid angle errors, the gap between the two
halves of the clutch must be measured at a 90° offset. The difference must be no greater than 0.05 mm.
If elastic bolts or denture clutches are used you must make sure to have congruent separations of the two
halves of the clutch. Changing the half clutches round is not allowed.
ATTENTION! Because of the danger of damages occurring on the bearings, hammering or knocking
the driving elements on is not allowed.

Pulleys are only allowed for generators of the type IM C2 as special feature design; they too must be dy-
namically balanced. Furthermore you must make sure to carefully align the two disks making up one pulley,
i.e. both shafts must be parallel to each other and the connecting line between the two disk centres must be
at a 90° angle to the shafts.
ATTENTION! Check the pull of the belt. For information about the max. admissible belt tension
please contact the manufacturer. Increasing the pull of the belt shortens the service-
able generator life.

Axial attitude of slide bearings

ATTENTION! When assembling of generators with slide bearings the axial attitude is to be kept ex-
actly. For the adjustment of the rotor in the magnetic centre the dimension X on the
bearing data sheet and at the bearing is indicated.

This dimension (see figure 4) must be checked after the coupling

has been mounted, and if necessary the alignment of the coupling
and generator must be corrected.

Figure 4: Dimension X

4.2 Electrical connection

ATTENTION! Only have specialized staff set up the electrical connection in accordance with appli-
cable safety regulations.
Observe all applicable national and international regulations. Connect the generator up according to the in-
formation given on the wiring diagram stuck on inside the terminal box. Refer to the wiring diagram for the
terminal points to connect the temperature winding protection, the bearing monitoring device, the speed con-
trol device, the standstill heating system, the exciter connections and additional transducers.

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ATTENTION! Connect the generators to earth using the corresponding protective earth terminals
inside the terminal box and on the foot of the generator stand.
Tightly set all connections to avoid high transitory resistances. At the same time permissible tightening
torques have to be held (according to DIN 46200):

Thread M 10 M 12 M 16 M 20
Tightening torque in Nm 10 15.5 30 52

Align the cable lugs at the largest possible distance to other connecting points and to the casing.
ATTENTION! Do not fall below the following distances between live components and to the case:

Rated voltage UN in V 550 725 1000 6600 11500

Minimal distance in mm 8 10 14 60 100

Round terminal bolts of low voltage generators (<1 kV) have not been designed to serve as conductors for
the rating current. You must therefore always make sure to put cable lug on cable lug (figure 5). If more than
three cable lugs are connected to one terminal, you should use a flat nut in between. Arrangement of cable
lugs, nuts and counter nuts is to be made according to the illustration below.

Terminal bridge

Wrong!
Figure 5: Cable lug arrangement inside the terminal box.

4.3 Terminal box and connections

The terminal box of low voltage generators (< 1 kV) contains the connections of the stator winding and all
other additional terminals required for generator operation and monitoring. Water-proof cable sleeves have
been provided for inserting the cables. The terminal box can be turned by 180° in relation to the insertion
opening. Prior to doing so you have to remove the additional terminal strip and attach to the opposite side.
For generator voltages higher 1 kV, the generators have got separate terminal boxes for the network connec-
tions and for the auxiliary and measuring connections.

4.4 Direction of rotation

The terminals are obligatorily marked in accordance with DIN EN 60034-8 / IEC 60034-8. If rotating right, i.e.
a clockwise direction of rotation seen from the drive unit side, a right revolving magnetic field occurs on ter-
minals U, V, W. If rotating left, the magnetic field revolves to the left unless something else has been agreed.
If you want to operate the generator as described above, you must connect the static current converter lines
to the regulator according to the circuit diagram. Should the network operate with right rotating magnetic field
two phases have to be changed on panel connection.

NOTE Generators that have been made to work only in one direction of rotation, this direction is
marked by an arrow on the generator, the ventilator or on the rating plate.
Contact the manufacturer if you want to change the direction of rotation of this type of
generator!

Direction of rotation Rotation right only Rotation left only

Direction symbol Î Í

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5 First start up
When putting the generator into operation for the first time or after long downtimes, the following checks
have to be made.

5.1 Electrical check

ATTENTION! All checks to be made by specialized staff only!
• Check whether all terminals are firmly connected and connections made to wiring diagram!
• Check condition of exciter and regulator connections!
• Check whether all monitoring devices are connected and set correctly!
• Check the system for proper earthing and earth conductors!
• Check whether voltage, frequency and rotary field of generator and network coincide before switching
the system on for the first time!
• Check the insulation resistances between winding and earth and between the parts of the winding.

5.2 Measuring of the insulation resistance

Danger!
Protect the system against unintended reactivation!
Earth the windings before and after the measuring of insulation at least 10s.
Don’t touch the windings before!

Measuring instrument: The measurement should be effected by a standard measuring instrument. Observe
exactly the operating instruction.
Measuring voltage: Observe the table below.
Measuring time: The measuring time should be 1 min at least.

ATTENTION! Disconnect the internal radio interference protection capacitors [10] before measuring
of the insulation resistance value.

The capacitors are attached to the exciter and connected to the generator frame via a cable. Disconnect this
line and re-connect it after measuring.
The following table serve to estimate the insulation resistance. Always estimate the insulation resistance (Ris) of
the cold generator, i.e. on room temperature (approx. 25 °C). “Warm-values“ are not to comprehend clearly.
The minimum insulation resistance on room temperature of a brand new generator or a repaired generator
with a new winding you find under item 1. of the next table.
This value can drop by virtue of transportation and storage under bad environmental conditions. In this case
the insulation is not damaged. Generators, which stand still under bad environmental conditions for a long
time and do not have a standstill heater (dew on the windings), can be started-up, so long as the insulation
resistance of the cold generator do not drop under the values like shown in item 2. of the next table.
Drop the insulation resistance under values of item 2, the windings must be dried. Under special operating
conditions the windings must be cleaned before drying (for that look to the section 6.5 “Drying the winding“).
The insulation resistance must rise after a short operation of the generator. Under normal transportation,
storage and operating conditions the insulation resistance of the cold generator must not drop under the val-
ues in item 2.

Table: Insulation resistances Ris

Voltage Rated voltage < 1.5 kV Rated voltage > 1.5 kV
Measuring voltage > 100 V to max. 500 V 1000 V
1. Winding new or repaired
Ris > 50 MΩ Ris > 100 MΩ
dry, 25 °C
2. Winding after long period of operation
Ris > 1 MΩ Ris > 5 MΩ / kV
condition unknown, 25 °C

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5.3 Mechanical check

• Make sure that the generator is clean and free from dust! Are removed all strange parts and tools?
• Check whether air inlets and outlets are clean, making sure that the air can enter and exit unobstructed!
• Check the temperature of the coolant!
• If you are working with a water-cooled generator, make sure that the cooling water circuit is properly
connected and operating!
• Check whether the generator and all screws fastening are connected correctly!
• Check whether the terminal box is closed and all wire entry sleeves properly sealed!
• Check the belt tension of belt-driven generators.
• In generators equipped with transport locking devices – marked by a special notice plate – check
whether the device has been removed.
• After longer storage periods, check the lubrication of the bearings (see section 6.2).
• We recommend first of all running every generator without load for at least one hour. The generator is
operating properly if it does not shake and if the noise of the bearings is even.

ATTENTION! Remove the transport locking device before starting operation.

NOTE To avoid environment pollution as a succession of transport damage the oil is drained out of
the bearing during transport by slide-bearing generators.
At generators with slide bearings the prescribed amount of oil (see data sheet) have
to be filled up absolutely! Make sure that the oil has the correct viscosity! A list of re-
commended oils is part of the documentation of slide bearings.
Then turn every generator rotor manually and listen to monitor it.

6 Maintenance
6.1 General information
Maintenance activities include bearings, cleaning the generator and the cooling air filters, if exist.
The following must be done according to operating condition but at least once every year:
• check the terminal boxes and terminals for cleanliness and corrosion

• check the electrical connections for tight fit. Maximal torques see section 4.2
• check the bearings for leckages of grease or oil
• check the cooling air circuit for cleanliness and sufficient operability.
6.1.1 Insulation value and standstill heater
Regularly check the insulation value of generators that are not used permanently or used in particularly
damp environments (see section 5.2 "Measuring of the insulation resistance").
If the generator is equipped with a standstill heater, then the heater bands and corresponding switching ele-
ments must be checked every six months.
6.1.2 Maintenance work at the drive
Danger!
In case of maintenance at the drive the short-circuited generators have to be de-ex-
citated absolutely according to section 2.1 by short-circuiting of the terminals
X100:3,"+" and X100:4,"-".
Earth-leakage circuit breaker and terminals for de-excitation should be interlocked.
NOTE Medium-high-voltage generators (type SEH) have to be short-circuited by an earth-leakage
circuit breaker in case of maintenance. The generator will be damaged if it will be driven in
this operation because it can be excited up to sustained short-circuit current.
6.1.3 Preventive maintenance
Depending on operating conditions, preventive maintenance is to be carried out every 15 000 to 24 000 h by
experienced and specialized staff.
Maintenance activities include cleaning the inside of the generator, checking bearings and close fitting of the
end-wire binding bands and, if necessary, applying a new coat of finishing varnish.
Check the alignment of generators and the safe connection of all screws.

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6.2 Lubrication and maintenance instructions for antifriction bearings

6.2.1 Lubricant information
The manufacturer lubricates the bearings in the factory using ADDINOL LM 3 EP, a lithium-based multigrade
grease of consistency class 3 with a temperature range of –40 °C to +140 °C (unless otherwise agreed).
We recommend also using this type of grease for relubrications. This is a sure way of avoiding damages to
the bearings due to wrong lubricants. The following lubricants can replace each other without limitations due
to useful characteristics or lubrication intervals.

Lubricant Manufacturer Lubricant Manufacturer

HL 3 ARAL Energrease LS 3 BP
Epexa 3 ELF MM - EP2 BP
Centoplex 3 Klüber Mobilux 3 / EP 3 Mobil
Alvania RL3 SHELL Unirex 3 ESSO
Total Multis EP3 TOTAL Turmoplex 3 EP Lubcon
Glissandro EP2-3 DEA SPEEROL AP3 Castrol

If new sort of grease will be used (with same consistency class and saponification also) the bearings should
be regreased 3 times with half regreasing periods.
In case of longer downtimes or storage please remember that the maximum storage time of these greases
is 36 months. So we recommend to regrease brand new generators too with half regreasing periods after
longer standstill time.
Check the proper functioning of the generator before and after each lubrication.
6.2.2 Bearings with relubrication device
ATTENTION! Lubricate the bearings only with the generator running.
Relubrication is done via the button head lubricating nipple in accordance with DIN 3404. All lubrication
points are marked on the generator. Information plates and the data sheet „Antifriction bearings” tell you
about lubrication dates and grease quantities.
In case the grease indicated for generators to be relubricated or another grease of the same type of saponi-
fication is not available, open the bearing covers and remove the grease. Then clean the bearing and relu-
bricate using a grease of a similar quality.
NOTE Avoid mixing greases of different type of saponification for roller bearing lubrication, because
the greases decrease their lubricity in this case.
NOTE Extending the recommended lubrication periods causes danger to the bearings and may lead to
a loss of bearing sealing usually provided by the grease thus allowing dust to enter the bearing.
By generators with low operation periods (e.g. emergency generators) it will be recommend
to regrease yearly with reduced grease quantity. A periodical putting into operation, at least
every three months, is important that grease in bearing will be worked through.

The used grease is automatically collected in a chamber underneath the bearing. The grease collector must
be emptied after three lubrication cycles unless otherwise stated. The grease collectors are marked by par-
ticular signs on the generator.
6.2.3 Removing used grease

Danger!
Remove the used grease only while the generator is standing still.

• It is mandatory to observe the dates for removing the used grease, because too much increased grease
quantities would lead to an impermissible warming-up of the bearings.
• In some generator types, the used grease comes out of a covered gap in the bearing lid, accumulates
around the end shield and must be removed from there after several lubrication cycles.
• Generators of type V1 are equipped with grease pipes on the D and the N side. To clean these, you re-
move the plugs on either side and push the used grease out to the left or right using a round stick
(Ø approx. 25 mm).
ATTENTION! Make sure to dispose of the used grease in an environmentally friendly way.
6.2.4 Bearings without relubrication device
Unless otherwise marked or agreed, generators up to type 250 are equipped with bearings with lifetime lubri-

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cation. The bearing producer calculate (appr. 20 000 h as life time. This value can fluctuate very much de-
pending on operating case (pollution, vibrations, temperature). So it will be recommended to open bearing
covers after 2 years operation and remove waste grease. The bearings have to be regreased.
For the bearings used see the Data sheet “Antifriction bearings”.
6.2.5 Maintenance instructions
Bearings have to be checked regarding to unusual sounds and admissible bearing temperatures periodically.
If there are SPM measuring nipples or vibration pickups, then the values measured must be analysed at the
same time intervals. To remove the hood or the end shield of bearings with relubrication device, you have to
separate the lubrication tube from the screw connection (see 6.6 “Assembly of bearings”).

6.3 Lubricating and maintenance instructions for slide bearings

The basis for the commissioning and maintenance of slide bearings is the enclosed original documentation
of the bearing manufacturer.
ATTENTION! The documentation must be carefully read before commissioning. Only strict and
careful adherence to these regulations ensures operation without faults!
6.3.1 Oil renewal
For this use the oil drain screw below the slide bearing.
NOTE It is recommend to exhaust the used waste oil. For that the screw is to remove above the oil
flow indicator (inspection glass).
6.3.2 Inspection of bearings
ATTENTION! At first the rotating rectifier [5] is to disassemble.
NOTE For generators with water coolers, the cover on the N side can be dismantled without remov-
ing the cooler cover.
To carry out the prescribed inspection of the bearings, the generator shaft must be lifted in this way, that the
lower bearing shell is unloaded and rotatable. As there is no suitable support surface on the N side behind
the aggregate frame or a lifting tackle can't be used, a cross bar can be screwed on the end shield as a
mounting aid (tapped holes exist for that).

6.4 Cleaning
Use a vacuum cleaner or bellows to remove dust from the generator, do not use pressurized air containing
oil or water. Make sure not to blow any dirt or dust into the inside of the generator. Do not use sharp tools
for cleaning!
If the winding is very dirty (oil vapours or grease squelching out of the bearings), use industrial solvent-based
cleaners (petroleum ether or diluter on petrol basis) or other aqueous industrial cleaners or emulsion clean-
ers to remove the dirt. Make sure that the cleaners do not dissolve paint coats or plastic materials.

ATTENTION! Provide sufficient ventilation when cleaning the generator and make sure not to let
any cleaning agents get into the waste water. Observe the environmental protection
regulations.
Cleaning cooling air filters
The filtering effect of the filter is achieved by a metal filter or layer of fiber filter element on the air inlet side.
Corresponding to operating conditions, clean the filter at regular intervals or after the thermal safety device
has reacted:
• Remove filter plate
• Shake or blow off loose dirt
• Wash the layer of fiber filter elements using water and solvent-free agents, then dry
• Wash metal filters with petroleum ether or similar solvents, blow through with air and then lubricate with
filter oil.

ATTENTION! Observe environmentally friendly disposal.

6.5 Drying the winding

ATTENTION! Only to be carried out by specialized staff.

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Check the heating up of the casing or measure the temperature of the winding by ther-
mocouples or a thermometer.
Selection of the drying method depends on the type of generator and the possibilities provided at the loca-
tion. Redrying can be achieved by warming up the winding using direct current (e.g. welding machine). The
current intensity used should not exceed 60 % of the rated current indicated on the performance plate. En-
sure power feed to two phases. Minimum drying time is 1 hour.
Generators with enclosed ventilation (IP 23) can be dried with warm air ventilators. Required drying time is
several hours. Generators can be dried while the generator is running and short-circuited stator winding. The
short-circuit can be produced immediately via the switch on the switching panel such that the stator current
can be monitored by an ammeter. Otherwise you have to measure the current in the generator directly. To
do so produce external excitation of the generator by an adjustable DC source.
Connection is made to terminals X100:3 (+pole) and X100:4 (-pole) inside the terminal box. Required setting
ranges are up to approx. 24 V for generators up to frame size 315 and up to approx. 48 V for generators up
to frame size 710. Required current intensity is < 5 A.
After drying you must measure the insulation resistance.

Drying conditions
• Keep check-up records with values measured!
• Always dry the winding slowly and thoroughly.
• The maximum drying temperature is 75 °C.
• Continue the drying process until the insulation resistance increases considerably and arrives at the
minimum value.
• Ensure condensation drain by opening terminal box and / or covers.
• Put the generator back into a normal operating state after drying.

6.6 Assembly of bearings

N-side
Replacing a bearing on the N-side required removing the end shield including the exciter enclosed in it. Pro-
ceed as follows:
• To remove the hood or the end shield of bearings with relubrication device, you have to separate the lu-
brication tube from the screw connection.
• Disassembly of lubricating tube (see fig.6)
Screw connection Disassembly:
Thrust collar
1. Push thrust collar against screw
1. Push connection
2. Pull at the tube at the same time

2. Pull Aassembly:
Push tube right in
Lubricating tube

Figure 6: Disassembly of lubricating tube

• Disconnect the cables connected to terminals X100:1 to X100:6 inside the terminal box and pull the ca-
ble through and in.
• Disconnect cables U, V, W from choke terminal strip or rectifier plate for exciter supply.
• Disconnect the primary winding cables of the current transformer.
• Carefully mark the primary cable of the static current transformer; during assembly observe direction K-L
of current flow (see functional diagram).
• Disconnect cables of the rotating rectifier stack.
• Loosen carrier disk and remove the rotating rectifier stack.
• Line the generator air gap.

NOTE Set the rotor such that one pole points down

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• Disassembly the bearing components, bearing lid, labyrinth box, excenter and remove the end shield in-
cluding the entire exciter unit after unscrewing the screws in the ring around the stator casing.

NOTE Use the attachment screws to remove the end shield from the centring device by screwing
them into the threads provided for this purpose.
• Pull out the old bearing and put in the new one after warming it up to 100 °C (water test).
• Lubricate the bearing. Completely fill the bearings to the rim with grease.
• Fill the gap between bearing lid and shaft with grease leaving the bearing lid empty.
Proceed in opposite direction for assembly making sure in particular to carefully connect all cables according
to the enclosed wiring diagram.

D-side
• Line the generator air gap from the N-side.
• Disassemble all bearing components and the end shield and change bearings as described for the N-side.

7 Supplementary installations
These only exist in customized solutions upon special request.

7.1 Temperature monitoring

7.1.1 Thermal winding protection
The thermal winding monitoring reacts to invalid temperature increases in the stator winding and is realized
by PTC thermistors or by platinum measuring resistors. They are included in the installation according to
agreement.
Rules and information given in section 4.2 "Electrical connections" apply.
Reactions are specified for problem conditions such as
• exceeding the rated power
• reduced cooler performance (e. g. congestion of the air filter)
• increased ambient temperatures

NOTE This protective systems only indirectly protects rotor and other windings.
7.1.2 Thermal bearing monitoring
According to agreement measuring and monitoring bearing temperatures are possible. To realize these op-
tions, sensors on the basis of PTC thermistors or Platinum measuring resistors and / or thermometers are
used after pressure-resistant mounting in corresponding screw-type casings.
The actual casing used depends on the corresponding end shield, crown or the bearing to be monitored.
Please refer to the wiring plan for the sensor connections inside the terminal box.
7.1.3 Thermal cooling air monitoring
For cooling air monitoring of generators with water/air cooler, air/air cooler or pipe connection, there is the
option of installing a Pt100 sensor and / or a thermometer at the cold air end (inlet).
If agreed, another sensor and / or a thermometer can be connected to the warm air side (outlet).
7.1.4 PTC resistor temperature probe (PTC thermistors in acc. to DIN 44081)
In this case, the sudden increase in thermistor resistance occurring in the range of ± 5 K of rated reaction
temperature is used for temperature monitoring. In an electronic module, this change in resistance is con-
verted to a signal which can then be used for switching off the generator or for outputting a warning.
PTC resistors with rated reaction temperatures between 90 °C and 170 °C are used.
Type designation includes the rated reaction temperature.
PTC thermistors in accordance with DIN 44081 can be exchanged or switched in series.
A typical stator winding has one PTC thermistor per phase. The stranded hook-up wires of these three ther-
mistors are series connected. It is possible to install a second set of thermistors which is then used in con-
junction with a second module either as reserve, for two separate windings or for thermal warning.
7.1.5 Platinum measuring resistors (Pt100 sensors in acc. to DIN EN 60751)
In this case, temperature monitoring is based on the linear change of Pt100 sensor resistances in a wide
temperature range. In conjunction with suitable temperature limit switches or Pt100 temperature measuring

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circuits they can be used for both automatic triggering at certain preset temperatures or for permanent
measurement, control or indication of temperatures.
Pt100 sensors can be installed in windings like thermistors.
Each sensor is connected separately to the terminal panel and must be analyzed separately.
Special Pt100 slot resistance thermometers can be installed in the generator slots according to agreement.
This allows very precise checking of the winding temperature and the sheet metal package even in very in-
accessible places.
Temperature control of components, cables and bearings in particular is possible by using surface sensors.

NOTE Create a four-wire connection by later adding two additional terminals in conjunction with a
terminal bridge or parallel terminals for the current and voltage wires (figure 7).

Figure 7: Four-wire connection

7.1.6 Silicon sensors (KTY sensors)

KTY series silicon sensors can also be used for temperature measurement and for limit value monitoring.
This series' silicon sensors are semiconductors with a similar design to a diode. Their working temperature
range extends from –55 to +300 °C.
Just like PTC thermistors, they have positive temperature coefficients. However, unlike PTC thermistors they
have an approximately linear characteristic curve. The resistance behaviour of KTY sensors is comparable
with that of a measuring shunt with large temperature coefficient.
KTY sensors are used analogous to the Pt100 sensors.
7.1.7 Note on repairs and retrofit packages
The module reacts to interrupting the stranded hook-up wires like to an increase to sensor resistance, there-
fore outputting the triggering signal. Stranded hook-up wire interruptions occurring in the accessible part can
be easily removed so that thermal protection resumes full operability. However, defect sensors require re-
placement.
Please make sure to first determine the resistance value for the defect sensor.
ATTENTION! The measuring voltage must not exceed 2.5 V max.
The Pt100 sensor resistance amounts for ambient temperatures of 20 °C approx. 108 Ω.
Put in new sensors in direct proximity of the defect ones always making sure not to remove the old ones to
avoid damaging the winding. See the relevant generator to find the exact mounting locations.
Unless otherwise stated, defect Pt100 sensors must be replaced by a 100 Ω resistor in the triggering device.
ATTENTION! This renders thermal protection ineffective.
Below the rated reaction temperature, PTC thermistors have a resistance of 20 – 250 Ω. For cases of ex-
change we will tell you the exact PTC type designation if you tell us the generator number.

KTY sensors may be replaced by the same types only. If you inform us of the generator number, we will no-
tify you of the precise KTY type designation.

7.2 Standstill heater

Standstill heaters are available for using the generators in shipbuilding, in tropical zones or upon request.
The standstill heater consists of heating pipes that are located inside the generator on the D- and N-side.

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Danger!
Switch off the standstill heater via the control centre before opening the terminal box!
Check whether the system is in a voltage-free condition.

The following heating output is customarily assigned to the shaft centre heights:

Shaft centre height in mm 225 - 250 315 - 400 450 - 500 560 / 630 710
Heating output in W 84 150 300 520 780

The connecting terminals are marked and located in the generator's terminal box.

The standard supply voltage is 230 V one-phase unless otherwise agreed. Connect the standstill heater to
the relevant terminals in the terminal box according to the current switching diagram.
Î For specific heater output and voltages : see information sign in the terminal box

ATTENTION! Activate the standstill heater only after switching off the generator.
Provide suitable means to avoid unintentional operation of the standstill heater while
the generator is running (locking mechanism).

7.3 Air filter

Observe maintenance instructions as given in section 6.4.

7.4 Additional protection and measuring transformers

Transformers can be put in for protection or measuring purposes upon request or if required by applicable
regulations. The transformers are located on the star point side of the stator winding. The transformer is con-
nected to the terminal box. Refer to the wiring diagram for measuring, auxiliary and monitoring instruments.
ATTENTION! Current transformers that are not connected must be short-circuited

8 Storage instructions
The generators should be stored vibration-free in a dry room free of dust. In this case, special packaging is
not required. Otherwise, the generators must be kept in plastic foil with humidity absorbing material. Provide
covers to protect it against rain and sun.
ATTENTION! Manually race the armature at regular intervals to avoid damage to the bearing.
NOTE Armatures of generators provided with transport locking devices are not raced as long as the
transport locking device is applied and functional. Observe the instructions given in section 5
prior to first operation

9 Troubleshooting
ATTENTION! Immediately switch off the drive if a failure occurs.
Carefully inspect the generator while in a voltage-free condition.

Danger!
While measuring or setting parameters with the generator running, you must be aware
of the fact that all unprotected terminals may carry very dangerous voltages and that
they are in immediate proximity to rotating parts. The generator must therefore be
locked to avoid contact by unauthorized persons.
ATTENTION! Check-ups of exchanging of parts must only be carried out by trained specialized staff
in accordance with IEC 60364 observing all applicable regulations of health care,
safety at work and fire protection.
The references to components correspond to the connection diagram of the generator.
9.1 Thermal and mechanical problems
Generator too hot:
• Check cooling air inlet and outlet and air filter and remove obstructions if necessary

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• Check whether the values given on the performance plate are kept (stator current, voltage, power factor,
unbalanced load)
• Check the coolant temperature
Unsteady generator operation:
• Check alignment of clutch and generator
• Check clutch status
• Check temperature of and noise made by bearings
• Exclude influences caused by the drive (e.g. ignition failures)
• Check whether all armature components are firmly attached

9.2 Voltage problems

If the generator produces no voltage or unusual voltages, try to find the problem in the exciter, unless a wind-
ing was found defective. The first step always is to check all connections and cables in the terminal box and
on the exciter components for proper connections and safe contacts.
ATTENTION! Use the wiring diagram for troubleshooting. Observe wire numbers and colours.

9.3 Checking and replacing the rectifier diode

The test is made with a continuity check instrument with a test voltage > 1 V. The diodes must forward the
current in one direction and not do so in the other direction.
Proceed as follows to carry out the check:
• Disconnect all poles of the unit prior to starting the check.
• Carefully pull off the flat-cable plugs.
• Check the through-state.

Stationary rectifier stack [8] Rotating rectifier stack [5]

Reverse the polarity of the continuity test instru- The modules are standard components used by most
ment for testing diodes 4, 5 and 6 (figure 8): manufacturers. Observe the electrical minimal values
when replacing a module. Make sure not to exceed
the following torques when reassembling (figure 9):

Screws: 5 Nm
Terminals: 3 Nm

Figure 8: Test instrument setting for stat. rectifier Figure 9: Test instrument setting for rot. rectifier

Minimal values for replacing the rectifier modules:

type forward current IFAV cut-off voltage URRM

Stationary rectifier stack [8] 25 / 08 10 A 600 V
Rotating rectifier stack [5] 81 / 08 80 A 800 V
81 / 14 80 A 1400 V

9.4 Testing varistors

The test is made as described for the diodes, the difference being that varistors must cut off in both direc-
tions. If any current is forwarded, the varistor is defective and needs to be replaced.

9.5 Replacing the regulator

Unscrew the 4 attachment screws and disconnect the wires. Replacing the unit is then possible without any
problems. Use a pen or screwdriver to open the terminals so that you can take out and disconnect the wires.

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ATTENTION! Carefully observe the terminal assignment plan. Wrong connections damages the
generator.
NOTE The system may have to be readjusted (voltage, static, stability) after replacing the regulator.
9.6 Problems overview
ATTENTION! For generator voltages < 1 kV measure the remanence voltage on the main terminals
only! For generator voltages > 1 kV measure the remanence voltage on the terminals
of auxiliary winding terminal X 020!
For safety reasons, you must interrupt the connection between stationary rectifier [8]
and stator winding [4] of the exciter before measuring the remanence voltage.
Do not touch voltage-carrying parts, as the remanence voltage is usually in the range
between approx. 5 to 10 % of the rated voltage.

Problem: Generator voltage too high and not adjustable during operation
Action Consequence Cause of failure, further actions
Check connection of external set-
point adjuster
Check function of step-down resis- Generator voltage - Step-down resistor R31 or connections defect
tor R31 is approx. 1.1 x UN - Replace resistor, repair line
- Regulator problem
Generator voltage - Replace reg. or go into emergency operating
does not change mode (section 2.9)
- Check air gap of choke [6] If the yoke is loose, set the air gap such that the
- Yoke and shims must be firmly systems sets itself to approx. 1.1 x UN at rated
attached speed and without voltage regulator

Problem: Generator voltage drops considerably under load

Action Consequence Cause of failure, further actions
Check speed of drive system Adjust speed regulator
Check rectifier stacks [5] and [8]
Replace defect elements
(section 9.3)
- Hand in to service if winding damaged
Check transformer [7] and cable 2 - Repair connections
Check static settings: put in jumper Generator voltage
Remove jumper for parallel operation and read-
and put load on generator must remain con-
just "Static" on the regulator
stant

Problem: Generator voltage rises under load

Action Consequence Cause of failure, further actions
Check connection of static current
transformer [11] and direction of ro- Connect properly
tation (see circuit diagram)

Problem: Wrong current distribution in parallel operation

Action Consequence Cause of failure, further actions

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Check connection of static current Remove jumper from static input of the regulator
transformer [11] and direction of ro- if it is in
tation (see circuit diagram) Connect up properly
Measure transformer current under
Current = 0 A Replace static current transformer [11]
load
Check performance-dependent dis-
Readjust speed regulator
tribution of active load
Check setting of no-load voltage of adjust no-load voltage on the regulator or via ex-
all generators (section 2.8.4) ternal set-point adjuster
- Readjust static on the regulator for the genera-
tor
- Observe in any case: if one generator accepts
too much reactive power during parallel opera-
Check whether static setting is even tion with static and increasing load, then you
must increase its static setting or reduce that of
the other generators (do not fall below about
2 % at rated current and p.f. = 0.8)!
(section 2.8.4)
For operation with compensating
line: Check the connection between
Check switch contact
generator terminal X100:3 – X100:4
and compensating line

Problem: Generator voltage too high or too low when putting into operation
Action Consequence Cause of failure, further actions
Check speed of drive system
Voltage o.k.
Modify voltage set-point Voltage setting Check connection of external set-point adjuster
range insufficient

Problem: Irregular generator voltage

Action Consequence Cause of failure, further actions
Check speed of drive system Adjust speed regulator
- Regulator defect
Change stability settings of the Voltage continues - Replace regulator
regulator to be irregular - Loose terminal
- Check connections

Problem: No generator excitation at no-load speed

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ATTENTION! Measure the generator voltage before trying to find the problem.
Action Consequence Cause of failure, further actions
- Check stat. rectifier [8] (section 9.3),
replace if defect
- Check rot. diodes [5] and varistor [S1],
replace if defect
No generator exci- Check current forwarding of rot. exciter winding
tation [2] on "+" and "-" bar of the rot. exciter [5]
- Check current forwarding of exciter winding [4]
Connect battery via reverse current of the exciter,
diode ("+" pole to X100:3 and "-" to do so disconnect wire 3 from X100:3,
pole to X00:4) X100:4 and measure between X100:3 – X100:4
Generator excita- - Remanence voltage was too low
tion to rated volt- - Immediately disconnect battery
age
Without battery - Check stat. rectifier [8] (section 9.3),
support voltage replace if defect
breakdown of gen- Check current forwarding of choke [6] between
erator voltage UVW and XYZ

Problem: Generator voltage to low and not adjustable during operation

Action Consequence Cause of failure, further actions
- Regulator problem
Generator voltage - Replace regulator or go into emergency operat-
- Deactivate regulator
is approx. 1.1 x UN ion mode (section 2.9)
- Disconnect conductor and run
generator - Check rectifier stacks [5] and [8] (section 9.3),
at rated speed Generator voltage replace if defect
does not change - Check the connections of choke [6]

10 Spare parts
The following information is required for ordering spare parts:

What? Where?
Name of part Enclosed spare parts list
Generator type Rating plate
Output ”
Voltage ”
Serial number of generator (absolutely necessary!) ”

Carry out dynamic balancing after replacing any rotating parts (with the exception of the rotating rectifier [5]).
Bearing configuration - see data sheet “Bearings”
Spare parts and names of parts - see appendix

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