Generator - Avk Dig 142 E-4 - En-Tlnr593588 [PDF]

Zitiervorschau

Contents 1

General Notes and Instructions Safety precautions Check list Maintenance schedule Customer contact list & Complaint report

2

Drawings Dimension drawing alternator Rotor drawing

3

Circuit Diagram Circuit diagram Legend to circuit diagram

4

AZ 12883 Rev. B 83611 Rev. B

K 840.1.29 Rev. G K 840.1.29 Rev. G

Operating Instructions Three-phase synchronous electrical machines series DIG 110...191 Enclosure to operating instructions

5

Regulator Descriptions Voltage regulator DECS 100

6

Bearings Recommendation for lubrication

8

Technical Data Technical Data Data sheet for PT 100 Information to explosion protection device Test report 8429800A002

GE Jenbacher Your order: GE#-875160-61 Your project: MM 1 - 4 620 AvK Order no. 8429800A002

03/2009

General Notes

General Notes Safety Precautions

Read this advice as well as the operating instructions supplied prior to commissioning or storage of the generator. Any works on the generator have to be performed by qualified and trained personnel only. Any person, working on the generator has to read and understand these operating instructions.

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

additional parts can be found in the documentation. The documentation, including the operating instructions, are part of the machine and have to be passed on to the next user in case the generator is sold or moved. 1.2 Liability and guarantee All statements and advice in the operating instructions are made under consideration of our present knowledge and experience. The technical information and data, described in this manual, is the correct state of information at time of printing. We reserve the right to changes due to technical progress without changing this operating instruction. Accordingly, no claims can be made from statements and descriptions in this manual.

We will not be liable for any damages or breakdowns due to operating mistakes in disregard of these instruction or improper repairs. We particularly point out, that spare parts and additional parts not supplied by AvK, have to be accepted by AvK. AvK will exclude any liability for damages that result from the use of spare and additional parts that have not been accepted by AvK. The installation or use of foreign products may possibly change the constructively given design of the electric machine in a negative way, and may restrict the safety of persons, machine or other values. Any unauthorized modifications and changes on the generator are not allowed for reasons of safety and will exclude any liability of AvK for resulting damages. If transformers supplied by the customer shall be installed in the terminal box, AvK has to be consulted first. The preceding notes do not extend the terms of liability and guarantee of the general delivery terms of AvK. Page 2

Manufacturer's Address AvK Deutschland GmbH & Co. KG Bunsenstraße 17 D-85053 Ingolstadt Phone (+49) (0)841 / 792-0 FAX (+49) (0)841 / 792-250 All rights reserved. Reprints or copies - even extracts need the permission of AvK. 2. Safety Precautions During transportation, installation, commissioning and maintenance, certain works might have to be performed on the generator, e.g. on feet support, shaft end, bearings, terminal box, etc. The working area and area of danger includes the surroundings of the generator and the prime mover. During normal operation, the working area should be limited to the operating and monitoring devices of the switchboard. Despite taking into consideration all safety precautions, the generator may be a source of danger, electrically and mechanically. To avoid damages to persons and values, all safety precautions have strictly to be followed. Beside all safety notes in the operating instruction the local safety precautions and rules for the prevention of accidents have to be followed. 2.1 Description of symbols and advice The following symbols are used in the instructions to highlight particular points and actions:

Follow all warnings and advice and act very carefully in these cases. Inform all persons working on the generator about all work-safety regulations.

2.2 Signs on the generator At particular dangerous points on the generator you will find safety notes. To avoid damages to persons or values these safety notes have to be followed very strictly.

Achtung! Betriebsanleitung Im Klemmenkasten! Vor Inbetriebnahme unbedingt lesen. Caution! Operating instructions are inside the terminal box. These must be read prior to commissioning. The documents for the generator are in the terminal box

Transportsicherungen. Vor Inbetriebnahme entfernen Transport Safety Devices Remove prior to commissioning. During transportation the rotor is secured against shifting. The transport safety devices have to be removed before commissioning.

Maschine nicht betriebsfähig! Machine out of order

Warning! Life in danger!

Danger!

Besides these safety notes all local valid instructions for safety and accident prevention have to be followed. Cummins Generator Technologies Germany GmbH POD-intro-AvK-eng-safetyprecautions.doc

This sign is mounted when the installation of transformers in the terminal box is necessary. The transformers have to be installed prior to commissioning. In this case the installation manual for the transformers is in the terminal box and in the enclosed documents. Page 3

E-Teile im Klemmenkasten

All safety devices like covers, barriers and protections have to be in place and must be functioning perfectly at all times.

Spare Parts are inside

Spare parts that are delivered with the generator are in the terminal box. The spare parts have to be removed.

It is not permitted to operate the generator with damaged safety devices!

2.3 Safety at site ABSTANDSMAß-PROTOKOLL AM GLEICHRICHTERTÄGER Mounting-distance test-report is inside

For the alignment of single bearing machines it is important to keep the mounting distance between rotor and stator on the NDE of the generator. The respective report can be found on the rectifier carrier at the NDE of the generator.

ACHTUNG! Vor Inbetriebnahme Öl einfüllen. Menge und Qualität laut Beschreibung Caution! Fill in oil prior to commissioning! Please refer to operating instructions of the sleeve bearing manufacturer for amount and quality. Generators with sleeve bearings need oil to be re-filled before commissioning. The instructions from the sleeve bearing manufacturer are enclosed.

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

2.2 Safety Devices 2.4 Safety precautions for maintenance Special covers are mounted to protect against mechanical danger (e.g. rotating parts). Protection against electrical danger is provided by covers and devices against over-voltage and over-current. It is not allowed to change or dismount any safety devices or to put them out of order. Unprotected machine parts may cause severe injuries.

Maintenance should normally only be performed when the generator is out of operation (except for the re-lubrication of anti-friction bearings). The prime mover has to be disconnected. After completion of the maintenance work, it must be ensured that all protection and safety devices are back in place properly. 2.5 Special Dangers

Cummins Generator Technologies Germany GmbH POD-intro-AvK-eng-safetyprecautions.doc

Page 4

The operator of the machine has to take care, that the rules for fire protection are kept and the equivalent agents for fire extinction are available near the machine and ready for use.

complete unit (generator and prime mover) •

For transporting the machine, the following devices are permitted:

-

Cable and chains,

3. Shipping, Handling, Storage

that comply with the local regulations, that have a sufficient carrying capacity, that are in an excellent working condition

3.1 Safety precautions for transport Please comply with the local valid regulations for shipments.

Warning! Never move persons!

loads

It is not permitted to use cables that are torn or worn. Cables and chains may not be knotted. Cables and chains must not touch any sharp edges.

over

-

Lifting devices:

•

The shipment and the unloading of the generator must only be performed by personnel, who are familiar with the lifting cranes and corresponding devices.

•

•

The lifting devices have to be designed for the weight of the generator (Chapter 3.4).

Moving the machine over rough ground e.g. rails, by using a haulage car is not permitted. This may cause damage to the bearings and the windings. This is especially important for the moving of the machine within the factory.

•

Follow the shipping instructions (pictographs) on the cover of the generator.

•

The generator must only be supported on its feet. The support on any other part is not permitted. That is why the generator is delivered with a transportation construction.

•

For the lifting of the generator, ring bolts are mounted on the generator housing.

Ring bolts, that are mounted on add-on pieces like e.g. the cooler top, must not be used to lift the whole machine! They are only used as mounting device for these add-ons. •

The ring bolts can only be used for the transport of the separate machine, they are not designed to lift the

Cummins Generator Technologies Germany GmbH POD-intro-AvK-eng-safetyprecautions.doc

cranes overhead cranes

3.2 Packaging The material used for the packing of the generator is made of ozone-friendly material – like wood. The packaging depends on the mode of transport used – surface, water or air freight. When the transport time is for a longer period, then the generator will be packed in a protective covering against dust or humidity. 3.3 Checking for Shipping Damage We recommend checking the generator for shipping damages and complete delivery by the time of delivery. If there are damages on the goods (open damages) report these to the haulage contractor at take-over. In this case, the receipt should only be given under reservation with a written statement regarding the estimated amount of the damage. Page 5

If damages that were not noticeable by the time of delivery (covered damages), are detected later, they have to be reported promptly to AvK, latest 6 days after receipt of the delivery. 3.4 Unloading the generator The unloading has to be performed in compliance with the safety precautions for transport (see chapter 3.1) and the local safety precautions and rules for the prevention of accidents. Please refer to the freight papers and the data of the respective order (Rating plate) for the weight of the generator. The weight of the generator is also written on the rating plate. 3.5 Storage of the generator After unloading, the generator and possible boxes with loose parts have to be stored until installation, following the shipping instructions. Wrapped parts and assessories must not be unwrapped if the generator is stored for a longer period of time. The machine and packages have to be stored in a safe place, dust-free and dry (humidity < 75%). Avoid mechanical vibrations and damages. If it is planned to store the generator for a longer period of time, please contact AvK for further information.

Cummins Generator Technologies Germany GmbH POD-intro-AvK-eng-safetyprecautions.doc

Page 6

Cummins Generator Technologies Germany GmbH Bunsenstraße 17 85053 Ingolstadt, Germany Phone: +49(0)841-792-0 Fax: +49(0)841-792-250 e-mail: [email protected] www.cumminsgeneratortechnologies.com

Cummins Generator Technologies Germany GmbH Dreieich Office Benzstraße 47-49 63303 Dreieich, Germany Phone: +49(0)6103-5039-0 Fax: +49(0)6103-5039-40 e-mail: [email protected] www.cumminsgeneratortechnolgies.com

Cummins Generator Technologies Germany GmbH POD-intro-AvK-eng-safetyprecautions.doc

Page 7

AvK Checklist to Order No.

Page 2

Customer:

.............................................................

Order No.:

.............................................................

Generator Type:

.............................................................

Operation Hours:

.............................................................

Bearing design:

Roller bearing

†

Sleeve bearing

†

Replacement of oil:

YES †

NO †

Bearing inspection performed:

YES †

NO †

I.

Electrical Inspection Pos. 1.1 - 1.19

II.

Mechanical Inspection Pos. 2.1 - 2.20

III.

Test Run Pos. 3.1 - 3.14

IV.

Maintenance Result

Cummins Generator Technologies Germany GmbH POD-intro-AvK-eng-checklist.doc

Page 2

AvK Checklist to Order No.

Page 3

Environmental Conditions:

a) Location:

building

†

marine

†

b) Atmosperic conditions:

dry dust

† †

high humidity salt

c) Ventilation:

unrestricted restricted

† †

† †

† †

adequate inadequate

Operating Conditions:

a) Site duty:

single

†

parallel

†

b) Duty cycle:

24 hours †

†

daily

c) Load condition:

inductive

†

non linear

†

d) Operation:

manned

†

unmanned

†

a) Dirt content:

slight dust thick dust

† †

b) Corrosion:

none, very little copper

†

idle

occasionally †

†

standby

Generator Conditions:

c) Engine:

Type: Serial No.: Fuel:

Cummins Generator Technologies Germany GmbH POD-intro-AvK-eng-checklist.doc

† †

light layer dirt thick compact dirt † †

steel/iron severe

† †

(....................)

.................... .................... ....................

Page 3

AvK Checklist to Order No.

I.

Page 4

Electrical Inspection

performed

Complaints see page 11

†

1.1

Examination of cable entry and cable shoes to main terminal box

†

†

1.2

Examination of strain relief of connecting power cables

†

†

1.3

Check of fixation of transformers installed

†

†

1.4

Examination of cable entry and cable shoes to auxiliary terminal box

†

†

1.5

Check of strain relief of connection cables

†

†

1.6

Insulation test of stator windings

†

†

a)

Stator winding phase U against ground Resistance ............. MΩ Voltage ............. V

†

†

b)

Stator winding phase V against ground Resistance ............. MΩ Voltage ............. V

†

†

c)

Stator winding phase W against ground Resistance ............. MΩ Voltage ............. V

†

1.7

Insulation test of stator windings

†

a)

Stator winding phase U against phase V Resistance ............. MΩ Voltage ............. V

†

†

b)

Stator winding phase U against phase W Resistance ............. MΩ Voltage ............. V

†

†

c)

Stator winding phase W against phase V Resistance ............. MΩ Voltage ............. V

†

†

1.8

Resistance measurement of stator

Cummins Generator Technologies Germany GmbH POD-intro-AvK-eng-checklist.doc

†

Page 4

AvK Checklist to Order No.

Page 5

performed

Complaints see page 11

†

1.9

Check and re-tightening of all screws and nuts in main terminal box by dynamometric key

†

†

1.10

Cleaning and examination of insulators for cracks

†

†

1.11

Re-tightening of contact screws and nuts on auxiliary terminal strip

†

†

1.12

Resistance measurement of auxiliary windings

†

†

1.13

Insulation test of auxiliary windings

†

†

1.14

Examination of anti-condensation heater

†

............. V †

1.15

............. A

Insulation resistance measurement of rotor winding

†

a)

Insulation measurement main rotor Resistance ............. MΩ Voltage ............. V

†

†

b)

Insulation measurement exciter rotor Resistance ............. MΩ Voltage ............. V

†

†

1.16

Resistance measurement of rotor

†

†

1.17

Inspection of rotating rectifiers

†

†

1.18

Inspection of stator end winding with endoscope

†

Inspection of stator end winding without endoscope

†

Inspection of rotor winding with endoscope

†

Inspection of rotor winding without endoscope

†

† † †

1.19

Cummins Generator Technologies Germany GmbH POD-intro-AvK-eng-checklist.doc

Page 5

AvK Checklist to Order No.

II.

Page 6

Mechanical Inspection

performed

Complaints see page 11

Sleeve Bearing Design Oil lubrication system installed: †

YES †

NO

†

2.1

Check of oil level in sleeve bearing

†

†

2.2

Check for leakage of sleeve bearings

†

†

2.3

Inspection of sleeve bearing with endoscope

†

Inspection of sleeve bearing without endoscope

†

† †

2.4

Check of oil quantity of oil lubrication system

†

†

2.5

Check of oil pressure of oil lubrication system:

†

.................... mbar †

2.6

Check of oil temperature of oil lubrication system

†

†

2.7

Check of oil pressure inside the bearing housing

†

.................... mbar †

2.8

Check of lubrication ring

†

†

2.9

Check for any corrosion on drive side and non-drive side bearing

†

†

2.10

Oil viscosity used:

†

Cummins Generator Technologies Germany GmbH POD-intro-AvK-eng-checklist.doc

according to ISO VG .................

Page 6

AvK Checklist to Order No.

performed

Page 7

Complaints see page 11

Roller/Ball Bearing Design †

2.11

Relubrication of roller/ball bearing according to operating instructions

†

†

2.12

Removal of surplus grease

†

†

2.13

Removal of old grease from bearing covers

†

Additional Mechanical Checks †

2.14

Inspection of abrasion of earthing brush

†

†

2.15

Inspection of base frame for mechanical deviations

†

Mounting of alternator / Check of feet fixation †

2.16

Visual inspection of the drive coupling

†

†

2.17

Check of inlet and outlet airducts for dust and dirt

†

†

2.18

Check of inlet and outlet airducts for corrosion

†

†

2.19

Cooler / leakage monitoring

†

†

2.20

Check of drainage stoppers / drainage for condensation water

†

Cummins Generator Technologies Germany GmbH POD-intro-AvK-eng-checklist.doc

Page 7

AvK Checklist to Order No.

III.

Page 8

Test Run

performed

Complaints see page 11

†

3.1

Check whether earthing switch is disconnected

†

†

3.2

Check of bearing noise

†

†

3.3

SPM bearing analysis:

DE:

LR ..........

HR ..........

†

NDE:

LR ..........

HR ..........

†

†

3.4

Check of oil amount in sleeve bearings during operation

†

†

3.5

Effectivity of lubrication ring

†

†

3.6

Tripping of temperature protector for check of alarm and shut down

†

†

3.7

Vibration test / Vibration values (mm/s)

†

DE:

.......... Hor.

.......... Ver.

.......... Axi.

NDE:

.......... Hor.

.......... Ver.

.......... Axi.

Frame:

.............

Airduct inlet:

Output:

............. kW

Cummins Generator Technologies Germany GmbH POD-intro-AvK-eng-checklist.doc

.............

Airduct outlet:

.............

Page 8

AvK Checklist to Order No.

Page 9

performed

Complaints see page 11

†

3.8

†

Check of regulator functions at no-load operation a) Exciter current at rated voltage and rated speed: I1-I1':

............. A

b) Exciter current at rated load: I1-I1':

............. A

c) Supply voltage:

d) Under speed protection: †

3.9

UH1-UH2:

............. V

UH1-WH2:

............. V

WH1-WH2:

............. V

H1 LED off

............. Hz †

Check of parallel operation Check of distribution of load Statics adjustment

.......... %

†

3.10

Check of overcurrent and short circuit protection trip

†

†

3.11

Check of differential protective trip

†

†

3.12

Check of exciter monitoring system

†

XE2 TO 109/110.1 †

3.13

† †

Check of generator voltage in parallel operation grid voltage min.: grid voltage max.:

†

............. kV ............. kV

Cummins Generator Technologies Germany GmbH POD-intro-AvK-eng-checklist.doc

Page 9

AvK Checklist to Order No.

performed

Page 10

Complaints see page 11

†

3.14

Bearing and winding temperature after continuous operation

†

__________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________

Cummins Generator Technologies Germany GmbH POD-intro-AvK-eng-checklist.doc

Page 10

AvK Checklist to Order No.

IV.

Page 11

Maintenance Result

Complaints: ___________________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________ †

The operation of the alternator can be continued without immediate elimination of the complaints.

†

Electrical and mechanical checks were performed without any complaints.

†

The alternator must be stopped immediately due to the complaints.

Date: ________________

________________________ (Signature Customer)

________________________ (AvK-Service-Technician)

Cummins Generator Technologies Germany GmbH POD-intro-AvK-eng-checklist.doc

Page 11

AvK Checklist to Order No.

Page 12

Cummins Generator Technologies Germany GmbH Bunsenstraße 17 85053 Ingolstadt, Germany Phone: +49(0)841-792-0 Fax: +49(0)841-792-250 e-mail: [email protected] www.cumminsgeneratortechnologies.com

Cummins Generator Technologies Germany GmbH Dreieich Office Benzstraße 47-49 63303 Dreieich, Germany Phone: +49(0)6103-5039-0 Fax: +49(0)6103-5039-40 e-mail: [email protected] www.cumminsgeneratortechnolgies.com

Cummins Generator Technologies Germany GmbH POD-intro-AvK-eng-checklist.doc

Page 12

Components

Exciter

Rectifier assembly Stator end winding

Protection equipment

Space heater

2

3 4

5

6

Frequency

6 month

12 month *)

approx. 25,000 h *) approx. 25,000 h *)

approx. 25,000 h *)

12 month *)

Frequency

12 month

POD-intro-AvK-eng-maintenance.xls

*) Maintenance frequency depends on the operating conditions at site.

Rotor windings

Additional components

General alternator check

1

Pos. B

1

Pos. A

Customer: Date:

Service / Steller

Caution: In case of heavy winding contamination please call the AvK Service Department. Check mechanical and electrical connections according to the supplier´s specification / manual. Ensure that the electrical heater is operating to prevent condensation. Check the power supply as well as the insulation resistance.

The insulation resistance must be checked with a megger when the alternator has reached ambient temperature. Remove any accumulated dust from the rotating rectifier and the exciter stator. Check if the electrical connections are secure. Remove dirt adhering to the rectifier unit parts. Inspect and remove deposits of dust, dirt and grease. Do not use any abrassive materials or fluids. Use only electrocleaner.

Maintenance

According to AvK Checklist.

Maintenance

Suggested Maintenance Schedule for AvK Order No.:

Cummins Generator Technologies Germany Gmbh

Date: 18.04.2000

Customer

AvK

AvK AvK

AvK

AvK

Carried out by

AvK

Carried out by

Page 1 of 2

Sleeve bearing: Oil seals

Sleeve bearing: Complete check

Oil pipes and flanges

Sleeve bearing: Oil level

Bearing earthing brush Dust filter

Cooler Complete alternator

9

10

11

12

13 14

15 16

Frequency

POD-intro-AvK-eng-maintenance.xls

Maintenance

6 month 100,000 h

3 month 3 month *)

monthly

6 month

25,000 h *) 50,000 h

6 month

6 month 6 month

Service / Steller

The oil seals must be changed. The bearing check must be done (according to supplier´s manual) and the oil seals must be changed. Check for oil leaks. After the first 500 running hours it is recommended to tighten the screws of the flanges again. The oil level must be visible in the viewing glass. (Approx. one third of the diameter.) Check the earthing brush for abrasion. At the appropriate intervals, the filters must be checked to establish their degree of contamination with dust and dirt. Check the cooler elements and leakage detector. Review with manufacturer for recommendations for full inspection / overhaul.

SPM bearing analysis. Ensure that the oil ring is rotating freely and picking up enough oil when the shaft is turning. Check for oil leaks.

Grease relubrication acc. Check oil or grease for any contamination particles. to supplier´s manual and/or name plate.

*) Maintenance frequency depends on the operating conditions at site.

Sleeve bearing: Oil ring

8

Additional components

Ball and roller bearings

7

Pos. B

Customer: Date:

Suggested Maintenance Schedule for AvK Order No.:

Cummins Generator Technologies Germany Gmbh

Date: 18.04.2000

Customer AvK

Customer Customer

Customer

Customer

AvK AvK

Customer

AvK Customer

AvK / Customer

Carried out by

Page 2 of 2

France french speaking North Africa

Italy

All AvK Products

All AvK Products

Switzerland

Stand: C vom 02.05.08

POD-intro-AvK-eng-customercontact.doc

Dokumentenname:

All AvK Products

All AvK Products

All AvK Products

All AvK Products

Spain Portugal

All AvK Products

Norway Sweden Denmark Finland Baltic States Russia North America South America Mexico Central America Canada Australia New Zealand South Pacific

UK

Countries

All AvK Products

Products

[email protected]

[email protected]

[email protected]

[email protected]

[email protected]

[email protected]

[email protected]

[email protected]

E-mail

Cummins Generator Technologies Germany GmbH

Martin Läderach

Theo Dragonas

Gary O`Malley

Jan Jakobsen

Guiseppe Cinnirella

Rene Moulin

John Johnson

Sarah Nicholls

Contact

Technical Service on-site (after warranty):

~1545

+61-(0)2-9680 ~2299

+41 317 408 282 Mobile: +41 7920 17561

C vom 02.05.08

Revisionsstand:

+41 317 408 280

~863-9243

TOLL FREE: (1) 800 ~367-2764

Mobile: +61-(0)412-886643

~5082

~45

~664

~9844

~104

Fax

1 von 2

DA 7.5-1

Direct: 001-763-574 ~5000

001-763-528-7301-6

+47-(0)22-9744~37

+39-(0)2-38000 ~714

+33-(0)16074 ~9843

Mobile: +34-(0)629183929

+44-(0)1780-484 ~767

Phone

Customer Contact List Service and Warranty Claim Handling for AvK Alternators

R.K. Kapur

India, Nepal

Countries

Worldwide

Stand: C vom 02.05.08

POD-intro-AvK-eng-customercontact.doc

Dokumentenname:

All AvK Products

Product

Norbert Steller

Norbert Steller Service Manager

Emilia Sandau

Phone

+49-(0)841-792 ~163 Mobile: +49-(0)171-221-9453

Phone

+91-(0)9811196343

+86-(0)510-521 ~6212 Mobile: +86-(0)139-5157-0763 +81-(0)354-415 ~588 Mobile: +81-(0)906-386-574

+62-214601685

Mobile: +65-(0)979-192-57

+65-(0)6794-3737/5

Emilia Sandau Assistant Service Manager

Cummins Generator Technologies Germany GmbH

Unterschrift:

von:

Issued 30.03.03

am:

Approved 30.03.03

[email protected]

E-mail

[email protected]

[email protected]

[email protected]

[email protected]

[email protected]

[email protected]

E-mail

Norbert Steller

Contact

Darryl Hanna

Jason Xu

(Indonesia)

Trisno Sumarlin

Anthony Tan

Richard Lee,

Contact

Japan, Korea

China

Singapore Malaysia Philippines Indonesia Thailand Taiwan Vietnam

Countries

Contact for Warranty Claims:

All AvK Products All AvK Products All AvK Products

All AvK Products

Products

Customer Contact List Service and Warranty Claim Handling for AvK Alternators

~195

~590

Fax

C vom 02.05.08

Revisionsstand:

~7673

+65-(0)6898-9065

Fax

2 von 2

DA 7.5-1

Drawings

Circuit Diagram

Seite 1 Page 1

Legende zum Schaltbild Nr. K 840.1.29 mit DECS100 Regler

Legend to Circuit Diagram No. K 840.1.29 with DECS100 AVR

F1 G1 G2 G3

Schutzschalter für G3 NUR IM STILLSTAND BETÄTIGEN Hauptmaschine Erregermaschine Hilfserregerwicklungen

Protection switch for G3 ONLY SWITCH ON AT STANDSTILL Main machine Exciter machine Auxiliary exciter windings

R11

Rotierender Varistor

Rotating varistor

T25

Spannungswandler

Voltage transformer

T32

V1

Spannungswandler für G3 mit integriertem Schutzschalter F1 F1 - nur im Stillstand betätigen! Rotierende Gleichrichter

Voltage transformer for G3 with integrated protection switch F1 F1 - only switch at standstill! Rotating rectifiers

X1 X2-7

Hauptklemmen Klemmleisten

Main terminals Terminal strips

DECS 100

Spannungsregler DECS100 oder DM110

Alternator voltage regulator DECS100 or DM110

Stromwandler für Strommessung Phase V ( B ) Übersetzung … / 1A

Current transformer for line B sensing input Ratio … / 1A

Messspannungsanschluß 3-phasig oder 1-phasig möglich, Bedienungsanleitung unbedingt beachten! 3-phasiger Anschluß: Verbindungen: U-E1, V-E2, W-E3 1-phasiger Anschluß: Verbindungen: U-E1, W-(E2 und E3)

Sensing voltage connection 3-phase or 1 phase possible, pay attention to DECS manual! 3phase sensing: connect: A-E1,B-E2, C-E3 1phase sensing: connect: A-E1, C- (E2 and E3)

Bedienungsanleitung DECS100 unbedingt beachten!

Pay attention to DECS 100 manual!

A13 A15

ZUBEHÖR Widerstandsthermometer PT100 Statorwicklung Phase U: 1, 4 Phase V: 2, 5 Phase W: 3, 6 Lager, B-Seite Lager, A-Seite

ACCESSORIES Resistance Thermometer PT100 Stator winding Phase U: 1, 4 Phase V: 2, 5 Phase W: 3, 6 Bearing, NDE Bearing, DE

H

Stillstandsheizung

Anti condensation heater

Stromwandler Für Schutz Kern Nr. 1: 1-6 Kern Nr. 2: 7-12 Kern Nr. 3: 13-18

Current Transformer For Protection Core No. 1: 1-6 Core No. 2: 7-12 Core No. 3: 13-18

Schnellentregung: Brücken UH1-24 und WH1-14 öffnen

Quick de-excitation: Open bridges UH1-24 and WH1-14

Verbindungen außerhalb des Generators Erstellt am: 26.6.08 geprüft von: Jansen Revision Nr.: 0

Connections outside the alternator Issued on: 26.6.08 Checked by: Jansen Revision No.: 0

T6

A1-6

T14-16

----

Operating Instructions

Operating instructions Three-phase synchronous electrical machines, Series DIG 110…191 with "COSIMAT N" voltage regulator

CONTENTS 1

Operating and maintenance instructions........................................................................ 3 1.1

Checking for damage incurred during transit................................................................ 3

1.2

Transport...................................................................................................................... 3

1.3 Storage ........................................................................................................................ 3 1.3.1 Preservation.......................................................................................................... 3 1.4 Setting up the machine ................................................................................................ 4 1.5 Cooling the machine .................................................................................................... 4 1.5.1 Coolant temperature ............................................................................................. 4 1.5.2 Direction of cooling air .......................................................................................... 4 1.5.3 Quality of cooling air ............................................................................................. 4 1.6 Dust filter...................................................................................................................... 4 1.6.1 Synthetic filter elements ........................................................................................ 4 1.6.2 Woven metal filter elements.................................................................................. 5 1.7 Preparations for starting up .......................................................................................... 5 1.7.1 Removing preservation ......................................................................................... 5 1.8 Machine drive............................................................................................................... 5 1.8.1 Belt drive............................................................................................................... 5 1.8.2 Coupling drive ....................................................................................................... 6 1.9 Aligning the machine.................................................................................................... 6 1.10

Changing direction of rotation................................................................................... 7

1.11

Electrical connections............................................................................................... 7

1.12 Starting up ................................................................................................................ 8 1.12.1 Insulation resistance ............................................................................................. 8 1.12.2 Operating speed ................................................................................................... 8 1.12.3 No-load operation ................................................................................................. 8 1.12.4 Parallel operation .................................................................................................. 8 1.12.5 Loss of remanence ............................................................................................... 9 1.13 Power factor regulation............................................................................................. 9 1.14

Interference suppression .......................................................................................... 9

1.15

Operation.................................................................................................................. 9

1.16

Maintenance............................................................................................................. 9

1.17 Bearings ................................................................................................................. 10 1.17.1 Ball and roller bearings ....................................................................................... 10 1.18 Drying out the machine........................................................................................... 12

Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DIG110191.doc

page 2 to 13

Storage

1 Operating and maintenance instructions

If the machine is to be stored after trial running, note the following points:

1.1 Checking for damage incurred during transit

1.3.1

Immediately after receiving the machine, inspect it for damage incurred during transit. The transport or delivering company must be notified of possible complaints immediately, or at the latest within seven days of delivery (covered by warranty).

1.2 Transport During transit, support the machine only on its feet. Do not allow the weight to be taken by any other components. Lift the machine at the crane rings attached to the stator housing. Note that crane rings on attached components such as the cooler assembly must not be used to lift the complete machine. They are intended only to simplify attachment of these components. In the case of complete machine sets on a base frame, use only the lifting facilities provided on the base frame. The crane rings on the electrical machine itself are not rated for lifting the complete machine set. If transported over long distances, it is advisable to protect the machine against environmental influences by sealing it in a plastic cover together with a quantity of desiccant (moisture indicator), so that it remains dust-free and air-tight. Machines with plain or taper roller bearings, and machines in a single bearing design are supplied with shipping brace. This shipping brace should never be removed until the machine has been set up in its future operating position on site. Install the shipping brace again if the machine is, for instance, to be shipped on or stored as a separate unit after trials. For transport as a complete machine set, take the necessary safety precautions, for instance support the machine set on anti-vibration elements or attach transit keepers.

•

Preservation

Complete machine

Store the machine in a dry, dust-free condition, for example heat-sealed in plastic foil into which a quantity of desiccant has been placed, or ventilated with dry air. Make sure that no moisture can condense on or in the machine and its attached assemblies. The machine must not be exposed to vibration while in storage. •

Shaft end, flange and bright metal areas

Clean rust and dirt off the bright metal surfaces and apply a protective lacquer coating. Make sure that the coating is not porous. •

Bearings

Sleeve bearings Drain the oil and apply a corrosion inhibitor to the bearing, for instance Tectyl 511 M in the case of sleeve bearings lubricated with mineral oil. If the bearings are lubricated with a synthetic oil, make sure that the bearing materials, the oil content and the preserving agent are all compatible. Ball and roller bearings To prevent brinelling marks caused by vibration when at a standstill, bearings should either be pre-loaded with a transit keeper or the rotor should be turned once a month to alter the position of the balls or rollers. The bearing’s grease content should be increased to the maximum. •

Cooler

Drain out the cooling water, clean the pipes, flush through with clean water and dry the complete cooler, using warm or pre-dried air. Check the efficacy of the protective treatment measures once a year. If ambient conditions are particularly unfavourable, check at more frequent intervals. If necessary, repeat the protective treatment.

1.3

Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DIG110191.doc

page 3 to 13

Setting up the machine The installation site must comply with the machine’s enclosure rating and be sufficiently large for cooling and maintenance purposes. When setting up the machine, make sure that: •

The relevant operation and maintenance safety regulations are observed

•

Cooling air can enter and exit freely

•

Exhaust gas and heated cooling air cannot be drawn in by the machine

1.4 Cooling the machine 1.4.1

Coolant temperature

Unless otherwise specified, the machine is built to run at a coolant temperature of up to 40°C and at an installation height of up to 1000 meters above mean sea level. Please refer to the machine’s data plate for coolant temperature and power rating. Coolant temperatures higher than stated on the machine’s data plate will result in power loss. Coolant temperature 45°C 50°C

Max. available power 96% 92,5%

If the machine is ordered to run at coolant temperatures higher than 40°C, this is shown on its rating plate together with the alteration in power rating.

1.4.2

Direction of cooling air

The machine is cooled by an integral fan dependent on the direction of rotation, mounted on the shaft. It draws cooling air through the machine and expels it at the fan side. To ensure proper cooling, make sure that the direction of fan rotation is as indicated by the arrow on the machine. If it is intended to use forced cooling, either alone or to support the integral fan, the direction of airflow and rotation must be correct here too.

Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DIG110191.doc

Important: The distance between the air inlet or outlet on the machine and any nearby wall must not be less than the dimension stated below, otherwise ventilation will be obstructed. Minimum distance (guide value): 1 x diameter of machine

1.4.3

Quality of cooling air

To extend the service life of the machine, and in particular its windings and bearings, it is extremely important that neither contaminated not aggressive cooling air be allowed to enter it. An air filter can be installed if requested by the customer, or can be trofitted provided sufficient space is available.

1.5 Dust filter If the machine is equipped with dust filters, please note the following points. •

The cooling air must not exceed the temperature stated on the machine’s data plate.

•

At the appropriate intervals, the filters should be checked to establish their degree of contamination with dust and dirt.

To ensure that the machine’s windings cannot overheat as a result of blocked filters, three temperature sensors are provided in the stator winding. These sensors must be connected to the warning system.

1.5.1

Synthetic filter elements

These are dry-type filters and must be cleaned at regular intervals, which depend on the amount of dust and dirt trapped by the filter. Filter elements can be cleaned with compressed air, water at a temperature not exceeding 50°C or a liquid detergent, but it is often a more economical proposition to renew them. Comply with all relevant environmental protection and safety regulations.

page 4 to 13

Woven metal filter elements These are supplied dry, that is to say not wetted with oil. They can either be operated dry or sprayed with special filter oil. If the filter elements are sprayed with oil, comply with the relevant environmental protection laws when cleaning them. They can be cleaned with a high-pressure

If the machine was given protective treatment following a trial run, the following measures must be taken:

1.6.1 •

Removing preservation

Complete machine

cleaning unit. Additives to dislodge grease can be used, provided that they have been checked for compatibility with the filter material. After cleaning, dry the filter elements and if necessary spray the with fresh oil.

Check the machine’s insulation resistance. If it is below the minimum value (see Chapter 1.12.1, Insulation resistance), the machine must be dried out. The procedure is described in Chapter 1.18., Drying out the machine.

Comply with all relevant environmental protection and safety regulations.

•

Regular cleaning of the filter elements is still needed even if the electrical machine’s windings are protected against overheating by built-in temperature sensors. Careful attention to this point will ensure that the machine always runs cool and reliably.

1.6 Preparations for starting up Pull the protective lacquer coating off the end of the shaft and the flange, or remove it with solvent. Never clean it off with emery cloth. Comply with the relevant regulations on environmental protection and safety. There is a threaded hole on the shaft, to which a puller can be attached for installing and removing discs or couplings. Hammering is not permitted, as this can damage the bearings. If the machine is delivered with shipping brace in position, remove it.

Shaft end, flange and bright metal areas

Remove the protective lacquer coating with a suitable solvent. Do not rub it off with emery cloth. Comply with the relevant environmental protection and safety regulations. •

Bearings

Sleeve bearings Dismantle and clean the sleeve bearings. The corrosion inhibiting agent must be removed. (this is not necessary if Tectyl 511 M was used and the storage period was fairly short, provided that the bearing is then lubricated with mineral oil). Fill the sleeve bearings with oil as stated on the lubrication plate and in the operating instructions. Ball and roller bearings Open the bearing housing and remove the additional quantity of grease which was previously added to the bearings so that only the specified amount remains in the bearing (see chapter on renewing bearings and lubrication plate).

If the machine is of single bearing design, its rotor is delivered attached to the shaft flange and the housing by a steel hoop to prevent axial displacement and is located in position radially between the shaft and fan housing by an angle bracket. Both these transit keepers (axial and radial) must be removed.

•

Make quite sure that the radial transit keepers are removed from the gap only after the rotor has been centred on the drive shaft flange. Failure to do so can result in damage to the exciter machine and the NDS (Non-drive-side) bearing.

1.7 Machine drive

In the case of machines with a steel disc coupling, the radial transit keepers are screws in the flange bell. They must be removed after the machine has been aligned and its position fixed in relation to the drive input.

Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DIG110191.doc

Cooler

Add water to the cooling circuit and operate it in accordance with the cooler manufacturer’s operating and maintenance instructions.

1.7.1

Belt drive

If the machine is driven by a belt, the machine must be ordered specifically with bearings and bearing lubrication to match the higher loadings. Most belt-driven machines have roller bearings on the input side. The rotor must be ordered with balancing by solid key, and the grooved belt pulley must be dynamically balanced on a smooth mandrel. The belt must run smoothly, without jerking. page 5 to 13

Desired balancing accuracy: ≤ Q 2,5 according to German VDI 2060 standard. When flat-type belts or V-belts which have already been in operation for a fairly long time are removed for maintenance purposes, they must be replaced by new ones (in case of hardening). Important: Belts that are tensioned too tightly can put the bearings at risk. For this reason, establish the correct belt tension with the belt manufacturer or the plant that supplied the machine, and have checks carried out on site.

1.7.2

Coupling drive

Unless expressly ordered otherwise, the rotor is balanced with a solid key. The grooved drive elements must therefore be balanced on a smooth mandrel. The coupling must be dynamically balanced to an accuracy of ≤ Q 2,5 according to VDI 2060. When installing the coupling on to the shaft end, make sure that no hammer-blows or shocks are transmitted to the machine’s bearings. Always use a suitable puller. When pulling the coupling on, comply with its manufacturer’s assembly instructions. Unless otherwise stated by the supplier, the coupling half can be heated up to 80°C. It can then be pushed on to the shaft end easily. Ensure that the drive element is securely located after tightening, and securely clamped against the mechanical stop on the shaft.

tolerances and clearances included with the machine. For further instructions, see the chapter on plain bearings. On machines with a steel disc coupling, radial rotor alignment is by means of centering screws inserted into the centering bell. These screws also act as transit keepers in a radial direction. They replace the pressboard inserts otherwise placed in the air gap. Alignment is checked by measuring the distance between the outer rim of the steel disc coupling and the machined inner diameter of the centering bell. In the case of single-bearing machines with a divide DS (drive side) end shield, accuracy of alignment is checked by measuring the air gap. If the machine has an undivided bearing plate, a machined end disc is installed at the drive side. The measurement is then made between the shaft and the machined inner diameter of the end plate. Take three measurements in each case, at 120degree intervals round the shaft. The results must not vary by more than 0,2 mm. This will ensure a uniform air gap beneath all poles and the correct axial position of the rotor. Check alignment accuracy at the end of the shaft or at the coupling. While checking, turn the coupling slowly through 360°C, at the same time taking the readings at the individual dial gauges. Attach one dial gauge radially and two axially, to compensate for rotor displacement. Refer to the coupling manufacturer’s data as a guide to permissible deviations from true alignment.

1.8 Aligning the machine Precise, careful alignment of the machine ensures that it runs with the minimum vibration, thus extending the service life of the machine and in particular of the bearings. This applies to machines with either flexible or rigid couplings. Even slight errors of alignment can rapidly result in damaged bearings. It is vital that all the feet are fully in contact. Uneven under surfaces cause stresses in the bearings and must be compensated for by attaching sheet metal strips. Once the machine is aligned correctly, secure it with dowel pins. When aligning a machine of single bearing design, it is important to comply with the reference dimensions specified on the dimension sheet and the drawing showing Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DIG110191.doc

Possible test method: Slowly turn the coupling through 360°C and determine maximum deflection of the dial gauge. M = dial gauge

page 6 to 13

Guide values

Shaft centre displacement

Shaft tilt

Coupling gap*

* Note coupling manufacturer’s data and allow for thermal expansion at the electrical machine and the drive.

If the coupling manufacturer specifies closer tolerances, always comply with them or obtain even lower values if possible. During alignment, remember that the length may increase as a result of thermal expansion in the machine. This change in length is approximately 0,1 ,, per meter of machine length and per 10 degrees Centigrade of temperature rise.

1.10

Electrical connections

The machine must be connected up according to the accompanying circuit diagram. The marked earthing (grounding) screw must be connected to the earth conductor. Installation is permitted by a qualified electrician only. Comply with the following points: •

VDE safety regulations or those of the local safety authorities

•

Local electricity supplier’s guidelines regarding protective measures

•

a) Have pressboard transit keeper inserts been removed from the air gap? b) Have the aligning screws been removed from the centering bell?

Phase sequence or direction of rotation of machine field as stated on rating plate

•

Correct direction of rotation as stated on the machine’s data plate

1.9 Changing direction of rotation

When connecting the cables, make sure that no mechanical forces can act on the machine’s connecting terminals. This also applies during assembly work.

In all cases, try to approach the ideal clearance values as closely as possible. Important points to be checked before starting up:

Before reversing the machine’s direction of rotation, it is important that the manufacturer be consulted. In most cases the fan is of a directional pattern and will have to be renewed. Note that the rotary field also changes with a reversal in the direction of rotation. If the machine is to be used in parallel operation, the sensing lead plug connections on the regulator (U and W) must be changed over so that connections U V W on the regulator again receive a right-handed field. The rotary field will change at the main terminals.

Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DIG110191.doc

Unused cable glands in the terminal box and machine must be protected against dust and moisture, and closed so that they cannot turn. Take up slack at all screw contacts and nuts. If current surges or vibration are to be expected, secure the cables with cable clips or racks. If the plant is set up on flexible mountings, ensure adequate clack in the cables.

page 7 to 13

1.11

Starting up

1.11.1 Insulation resistance After a long period out of use or in storage, the machine’s insulation resistance must be measured. Before starting up any machine, measure the insulation resistance of the winding between phases (if the star point is separate) and between phase and earth. All parts not subjected to the measuring voltage must be earthed. When measuring the insulation resistance, all connections (main connection, measuring connection, connection to regulator and protection or suppression circuit) must be disconnected from the winding. The suppression elements and measuring leads must be disconnected during high-voltage insulation tests and tests with insulation measuring appliances. Measure at 500 V DC on low-voltage machines (< 1 kV) or at above 2 kV on high-voltage machines (≥ 1 kV). Due to the capacitive charge in the winding, the measuring unit indicates the correct insulation resistance value only after several seconds have elapsed. Earth the winding immediately after the measuring voltage has been switched off. If the insulation values are too low, first check the terminal insulation for dirt and moisture. Clean or dry them as the case may be, and repeat the measurement. Damp windings can lead to current leakage, flashover or breakdown. If insulation resistance on new, cleaned or repaired windings is less than that stated below, drying out is needed (see Item 1.18, Drying out the machine).

Where UN is the nominal voltage of the machine expressed in kV. When testing insulation and measuring the windings, these must be connected to the posts or bars as the case may be, so that these parts are tested as well. Secondary connections such as measuring connections to transformers and all connections to regulating, protection or interference suppression circuits, must be tested separately. Each of these connections must be checked individually at the terminal strip. This also register the insulation resistance of the terminal strip. Use a maximum test voltage of 500 V DC for all secondary and measuring connections. Insulation resistance should not fall below 5 MΩ.

1.11.2 Operating speed The machine’s speed must correspond to the value stated on its rating plate. The machine must run smoothly, both at no-load and when under load. If the drive machine runs at reduced speed, the voltage regulator’s under speed protection cuts in and de-excites the machine. Irregular running will lead to deviations from the nominal ratings. The machine is voltage-regulated and maintains a voltage accurate to ± 1% in any condition between no load and full load, even if its speed fluctuates by ± 5%. In the case of special versions, the order values confirmed by the manufacturer should be adopted.

1.11.3 No-load operation The no-load voltage can be adjusted within a range of UN ± 8% by connecting the voltage setting rheostat to terminals s and t.

On low-voltage machines with a nominal voltage below 1 kV, and in the rotor winding, insulation resistance should not be less than 5 MΩ at a winding temperature of 25°C.

The voltage regulator ensures that the voltage remains constant as the machine warms up to its normal operating temperature.

In the case of medium- and high-voltage machines with a nominal voltage equal to or greater than 1 kV, the insulation resistance in MΩ must be calculated using the following formula:

1.11.4 Parallel operation

R ≥ 3 + 2 x UN

Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DIG110191.doc

Machines operated in parallel are equipped with a damper cage. They can be operated with identical or dissimilar machines or if necessary in parallel with the mains.

page 8 to 13

The three familiar preconditions for parallel operation must be complied with: • Identical voltages • Identical frequencies • Identical phase angles Matching can be carried out manually or by an automatic synchronizing device. For further details, see the supplier’s technical description. In parallel operation, a distinction must be made between active and reactive load distribution.

1.14

Operation

During operation, current-conducting and rotating parts must be sealed with the covers provided for this purpose. Increased vibration may result from insufficiently assert alignment, poorly fitted foundations or frame, or weak mountings. In addition, vibration can be introduced from the drive and non-drive sides.

1.15

Maintenance

Active load distribution depends only on the speed characteristic of the drive and cannot be influenced by the electrical machine itself.

Before starting work on the machine make sure that it is switched off and take action to prevent it from being switched on again.

Reactive load distribution is determined by the electrical machine’s voltage characteristic, according to load.

Ensure that machine components which are live during operation are at zero voltage (by earthing or disconnecting the wiring).

1.11.5 Loss of remanence

All work must be performed by qualified staff possessing the necessary knowledge and experience.

If the auxiliary exciter machine (G3) has lost its remanence, that is to say there is no voltage at terminals UH1-UH2 and WH1-WH2, terminal I2 (+) and K2 (-) must be excited briefly with a DC voltage (1,5 – 12 Volt) while the machine is running.

1.12

Power factor regulation

For operation in parallel with the mains the machine can be equipped with an additional automatic power-factor regulator (for pre-set co phi range, see test report). For further details, refer to the description and adjustment instructions for the additional "Cos" power-factor regulating module in conjunction with the "COSIMAT N" voltage regulator.

1.13

Interference suppression

The machine comply with radio inteference requirement "N" as stated in German VDE 0875. Note that the standard of interference suppression is related to the quality of earthing. Disconnect suppressor capacitors, measuring transformers and regulators during high-voltage insulation tests or if insulation measuring equipment is in use (if the test voltage reaches 80% of the factory’s test voltage).

If there is moisture or dust in the terminal box, it must be removed from the surface of the insulating parts. The reason for the accumulation of moisture or dust must then be established and rectified. If severe dust occurs, the electrical machine should be blown through at regular intervals with dry compressed air, as it is running down to a standstill. Clean the machine’s surface regularly as well, to prevent dust and dirt from building up and adversely affecting the dissipation of heat. Make sure that the air inlets and outlets are not obstructed during operation. Apart from the bearings the dust filters (if installed) and the attached cooler, the machine requires no routine maintenance. If carbon brushes are installed on the machine in equipment designed to perform various monitoring functions, they must be checked for wear at regular intervals. If the machine has add-on equipment, for example a cooler, the additional maintenance instructions issued by the manufacturers of this equipment must be complied with. Like any other machine, the electrical machine requires to be treated with care.

Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DIG110191.doc

page 9 to 13

Each of the machine’s bearings is normally provided with a relubricating device. If a duplex NDS bearing is installed, note that there are two grease nipples for relubricating. Refer to the appropriate column in the lubrication chart for the correct volume of grease per nipple. Re-greasing should be carried out with a grease gun at the nipples provided on the machine.

Re-lubricating quantity

The machine’s bearings must each be relubricated with the amount of grease stated. Remove expelled grease from the bearing points. When re-lubricating the bearings, run the machine if possible at half speed for one hour to distribute the grease effectively. During this period, check the temperatures of the bearings and compare them with the temperatures recorded before relubricating.

Lubrication chart Type

bear-

A regulator is installed to control grease volume, so that old grease is expelled from the bearing.

•

Re-lubricating the bearings

Ball and roller bearings are supplied ex- factory packed with high-quality anti-friction bearing grease and are therefore ready for immediate operation. Machines with re-lubricating devices bear a plate on which the following information is stated: Re-lubricating interval in hours of operation Quantity of grease Type of anti-friction bearing grease •

DIG

Before re-greasing, clean the nipple so that dirt cannot enter the bearings. Where possible, apply grease when the machine is running at reduced speed, unless this represents a hazard for the operating personnel.

Lubrication Re-lubrication intervals in hours for machine running points* Quantity in speed of: g

120/ … 121 130/ … 131 140/ … 141 150/ … 151 156

1500-1800 min-1

The standard bearing specification is as follows: on the drive side, a roller bearing, on the nondrive side, a ball bearing or a duplex bearing consisting of one roller bearing an one ball bearing.

•

1000-1200 -1 min

If the bearings on either side are of the deep groove ball bearing type, they are pre-loaded in relation to each other by spring elements, this ensures smoother running and reduces the negative effects of external sources of vibration on the bearings. Deep-groove ball bearings are installed at both bearing points only to special order.

Under adverse operating conditions, e.g. a humid atmosphere, relatively high dirt accumulations, severe vibration loading etc., the re-lubricating interval must be reduced accordingly. If the permitted coolant temperature is exceeded by app. 15°C, the re-lubricating interval must be halved.

750-900 min-1

The machine is fitted with anti-friction bearings. The DS has a floating bearing, the NDS a fixed bearing.

500-600 min-1

1.16.1 Ball and roller bearings

Machines which have not been run for very many hours must be re-lubricated at least once a year. If the stated re-lubricating interval is below 1,200 hours, re-lubricate twice a year.

Double bearing

Bearings

Single ing

1.16

60

40

2500

2000

1500

1000

80

60

2500

1500

1200

800

100

60

2000

1500

800

600

100

60

2000

1000

800

600

100

60

1800

900

700

500

* In the case of double bearing, the amount of grease stated in the "double bearing" column is to be injected into each of the grease nipples.

Re-greasing interval

Bearing must be re-lubricated regularly in accordance with the specified re-lubricating intervals (see chart).

Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DIG110191.doc

page 10 to 13

•

Ball and roller bearing greases

On delivery, the bearings are lubricated with highgrade, lithium-saponified grease of Grade 3 consistency )NLGI classification). The factory uses Shell Alvania R3 for this purpose. The grease channels and the channel between the nipple and bearings are filled with anti-friction bearing grease before leaving the factory. The following alternative types of lithium-saponified anti-friction bearing grease may be used: Shell Alvania R3 Arcanol L71 Or a lithium-saponified brand-name grease of equivalent specification, heat-resistant up to at least 130°C and complying with German Industrial Standard DIN 51825. Recommendation: Always re-lubricate the bearings with the same selected brand of grease. •

Dismantling the bearings

During shaft production, the bearing seat and the bearing stop shoulder on the shaft are subject to particularly stringent quality control. This is essential to maintain the accuracy of shape needed to keep the bearings fully operational. When dismantling the bearings, it is therefore important to handle the bearings and bearing rings with particular care, otherwise the bearing seats on the shaft and bearing plate could become damaged. To simplify dismantling, the parts can be heated uniformly all round to a temperature of app. 80°C. Do not install bearings previously removed, but renew them. •

Assembling the bearings

Bearings must only be renewed by a qualified person possessing the necessary knowledge and experience, working in a dust-free environment, on a clean surface and using suitable tools including metric wrenches. The grease and bearings must be kept free of impurities, otherwise they will wear out faster and possibly even fail. The correct arrangement of the bearing components must be retained, this applies particularly in the event of repair work.

disk should be rigidly attached to the shaft. Do not remove new bearings from their packs until just before they are installed. Do not wash the bearings out, as the anticorrosion agent applied to them is compatible with most customary antifriction bearing greases. Clean the parts of the bearing that are to be reinstalled. Before fitting the bearing, check for dimensional accuracy and lack of distortion at the bearing seats on the shaft and in the housing. When single-piece bearings (e.g. deep-groove ball bearings) are installed, the force exerted to fit them must always be applied to the firmly located race, which has to be mounted first. Forces applied to the free-moving race have to be transmitted through the balls or rollers, which can damage them and their tracks. Installation of separable bearings (e.g. roller bearings) is more straightforward. The two races can be installed separately. A screwing movement when assembling them helps to avoid rub marks. When fitting the bearing on the shaft, heat it to about 80°C in an oil bath, oven or by a suitable inductive heating method. Make absolutely sure that it is located centrally and in positive contact with the shaft shoulder. Once they have cooled down, pack the bearings fully with grease. The inner and outer bearing covers must each be filled with grease to approx. 50% of their full capacity. •

Monitoring the bearings

The first indication of damaged bearings is usually a noticeable change in temperature or running behaviour, or noise and vibration if bearing damage has reached and advanced stage. Recommendation: Monitor the bearings by measuring transmitted noise and vibration at regular intervals, and compare the readings with those taken on previous occasions.

When renewing bearings, install original typeapproved bearings only, and maintain the correct amount of bearing play. The grease regulating Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DIG110191.doc

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1.17

Drying out the machine

To protect the machine against moisture, the builtin heating should always be switched on when the machine does not emit any heat of its own. Even a slight increase in the temperature of the air inside the machine will prevent moisture condensation on the insulating components. If the machine’s insulation value drops below that stated in the chapter "Insulation resistance", the machine must be dried out. In many cases it can be dried suitably using its own ventilation system, but it should not be electrically live while this is being carried out. Deexcite the machine as indicated in its circuit diagram. Operate the built-in heating when drying out with the machine’s own ventilation system.

Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DIG110191.doc

If no improvement in the insulation resistance is registered after a running period of approx. 2 hours, the machine must be dried out additionally with dried air supplied from the outside. If this in turn does not increase the insulation resistance after approx. 4 hours, the machine must be dried out by passing an electric current through the stator and rotor windings. However, this task requires special knowledge and must therefore only be performed by personnel that has received specific training. Please contact our service organisation in this case. For additional information on bearing renewal or special operating conditions such as run-up synchronisation, rapid excitation or deexcitation, please do not hesitate to contact our engineers.

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Cummins Generator Technologies Germany GmbH Bunsenstraße 17 85053 Ingolstadt, Germany Phone: +49(0)841-792-0 Fax: +49(0)841-792-250 e-mail: [email protected] www.cumminsgeneratortechnologies.com

Cummins Generator Technologies Germany GmbH Dreieich Office Benzstraße 47-49 63303 Dreieich, Germany Phone: +49(0)6103-5039-0 Fax: +49(0)6103-5039-40 e-mail: [email protected] www.cumminsgeneratortechnolgies.com

Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DIG110191.doc

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Enclosure to Operating Instructions Advise for Commissioning

Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DSG29144(ohne Cosimat).doc

page 1 to 11

Generator with vibration absorbers on foundation

in order to avoid relative movements between the cable fixing and the terminal

box. By connection of the cables it must be ensured that no forces have an effect on the machine connection terminals. The same counts for the time during assembly. If shock load or vibrations are to be expected, the cables should be fixed over the cable clips and the cable platform.

The relative movements between the genset and the foundation have to be compensated for by a sufficiently long free cable length between the cable fixing on the gen-set and the foundation.

By elastic mounted gen-sets (see picture above) sufficient 'free cable length' should be ensured to compensate the movements of the diesel/gas motor. In order to ensure that the movements do not have a negative influence on the connection terminals, the cable must be fixed with max. 300 mm distance from the terminal box screw fitting. This cable fixing has to be connected rigidly to the gen-set Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DSG29144(ohne Cosimat).doc

page 2 to 11

Generator with vibration absorbers on frame base

By connection of the cables it must be ensured that no forces have an effect on the machine connection terminals. The same counts for the time during assembly. If shock load or vibrations are to be expected, the cables should be fixed over the cable clips and the cable platform. By elastic mounted gen-sets (see picture above) sufficient 'free cable length' should be ensured to compensate the movements of the diesel/gas motor.

Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DSG29144(ohne Cosimat).doc

In order to ensure that the movements do not have a negative influence on the connection terminals, the cable must be fixed with max. 300 mm distance from the terminal box screw fitting. This cable fixing has to be connected rigidly to the gen-set in order to avoid relative movements between the cable fixing and the terminal box. The relative movements between the genset and the foundation have to be compensated for by a sufficiently long free cable length between the cable fixing on the gen-set and the foundation.

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Connections

Stützer für Innenanlagen Insulating supports for indoor use Anzugsdrehmoment / tightening torque M12, 50-70 Nm Anzugsdrehmoment / tightening torque M16, 90-110 Nm 6 Kt. Schraube: Stahl 8.8 hexagon bolts: steel 8.8

Durchführungsklemme DIN 46265 Duct terminals Anzugsdrehmoment / tightening torque M12, 20 Nm Anzugsdrehmoment / tightening torque M16, 40 Nm Anschlussbolzen: Ms / connection bolts: brass Anschlussmutter: Ms / connection hex. Nut: brass

Cable connection acc. to DIN 46200

Using the Protection switches Q1, F1, F2

Elastic parts, such as spring washers, can be used in the electrical connection, however, only on one side of the clamped conductor. If necessary, additional washers are to be used. The other side is for current conduction, why only washers or security locking plates of copper-zincalloys must be used.

The purpose of these switches is to protect the voltage transformers T24 (Q1) and the auxiliary exciter winding (F1, F2). In case of failure, these switches will lead to a quick de-excitation of the machine.

By electrical connection with eyelet rings, the eyelets have to be protected by washers on both sides against bending.

De-excitation Open the bridges UH1-24 and WH1-14 on the terminal strip X2. De-excitation with extern switch takes place on these terminals, too.

Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DSG29144(ohne Cosimat).doc

These switches are not to be used for deexciting the machine during operation or maintenance!

Open star point The voltage transformer T24 has to be disconnected and the cables sufficiently insulated! De-excite the machine as described above. No tests are to be performed with open star point! The correct connection of the power cables can be checked with appropriate equipment.

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Maintenance for earthing brush

Optimum maintenance and care for earthing brushes is the base for smallest brush wear. The maintenance of brushes must take place after certain intervals that depend on the alternators size as well as load and ambient conditions. Brushes are subject to wear and tear and must be cleaned by air (pressure or suction) from time to time. Routine check every 3 months is recommended by AvK to ensure about operational behaviour and suitable changing intervals.

Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DSG29144(ohne Cosimat).doc

All brushes and holders must be checked for free movement. Blocked brushes may lead to damage. Worn out brushes must be renewed in time, so that damages at the contact surface on the shaft can be avoided. New earthing brushes do not need grind-in (other than slip rings). Using brushes bigger than the original size is only possible after agreement with the supplier.

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Maintenance of Earthing Fault Monitoring

Optimum maintenance and care of the brushes and slip rings is the base for smallest wear. The maintenance must take place in certain time intervals. The frequency of the maintenances depends on alternator size as well as on load and ambient conditions. Brushes are subject to wear and tear and must be cleaned by air (pressure or suction) from time to time. Routine checks every 3 months is recommended by AvK in order to estimate the necessary time intervals during the actual operation conditions.

only possible after agreement with the supplier.

Note: The Earthing Fault Monitoring is mounted on the NDE of the machine. Attention: Maintenance works must be performed only during standstill of the machine.

All brushes and holders must be checked for free movement. Blocked brushes may lead to damage. Worned out brushes must be replaced in time in order to avoid damages on the slip rings and to ensure the perfect function of the Earthing Fault Monitoring. New brushes need grind-in with the slip rings. The use of larger brushes than originally mounted is Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DSG29144(ohne Cosimat).doc

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Electrical Machines with two shaft ends

Anti - condensation heater:

Bearing currents by electrical machines with two shaft ends must be avoided. AvK recommends an insulated coupling mounted on the NDE.

The anti condensation heater is to be connected according to correct rating and supply voltage. Please refer to rating plate of the machine.

Another possibility is that all bearings of the NDE aggregate are insulated.

Control of the anti – condensation heater should be done that the heater -

is switched on after the machine has stopped, is switched off before starting up the machine.

Tubular heater type RHK T + H art. no. 100870 and 100872 Description 2 heaters type RHK dia. 8, 5mm x 500mm long assembled into two brackets made of stainless steel as per our drawing no 31522, heaters wired in parallel by brass brackets, silicon insulated connection cable 3000mm long. Number of heater elements is according to required heating power. Technical data of the heaters Heater sheath: AISI 321 Heater wire:

Chrome-Nickel-Steel

NiCr 8020, Mat. no.: 2.48869

Insulation material: pure magnesium oxide, highly compacted Connection: threaded bolt M4 with silicon insulated cable Tolerances Diameter of heaters: 8,5mm ± 0,15mm Straight length of heaters: 500 ± 2 % Wattage per heater: 500 Watt ± 10 % Total wattage (4 heaters):1000 Watt ± 10 % Voltage: 230 Volt Dielectric strength: 1250 V Final test: per standard DIN EN 60 335 Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DSG29144(ohne Cosimat).doc

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Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DSG29144(ohne Cosimat).doc

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Bolting torque for fixing screws

Dust filter made of metal fabric

If no further indications are made , use the following bolting torque for connections of fixing screws and fixing nuts:

Description

screws property class 8.8 M4 M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 M42

3,0 3,5 9,0 18 45 50 110 250 440 980 1730 2700

screws property class 4.6 1,1 2,2 3,7 9,0 18 31 75 150 255 510 890 1450

starting torque in Nm Values according to VDI 2230 calculated considering the maximal admissible surface pressure under the screw head and a frictional co – efficient µ ges = 0,125

Design of the filter The frames and the plates of the filter are fabricated of: • Constructional steel with zinc coated mesh wire • Stainless steel with stainless steel mesh wire alternatively depending on application conditions Type of filter B1 EU2

according to DIN 24185 / part 100 according to DIN 24185 / part 2

Medium degree of deposition 65 ≤ 80 % Maintenance The maintenance intervals depend on the local dust accumulation. The dust protective filter plates have to be cleaned with the usual commercial detergents. Cleaning with high-pressure cleaning devices is also possible. Caution: Do not wet the filter plates with oil! Observe the instructions for pollution control.

The following detergents can be used when cleaning mechanically: Calgonit / equivalent)

Somat

/

Topmat

760 (or

If only a manual cleaning is possible, use the following detergents: Rivonit / RG 1083 (or equivalent) Regular checks and cleaning of the dust protective filter system is indispensable for the safety in operation of the electrical machines

Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DSG29144(ohne Cosimat).doc

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P5

All wedges welded Fixing pins Ø2 Enforcement over L500 2 pieces Screen 20*20*2

2/1 angle bracket

25-1

B

10

1

a

L

20*3

=

20

20

20

=

a

2*Ø7-200 3*Ø7-400 4*Ø7-600 5*Ø7-800 6*Ø7-1000 7*Ø7-1200

10

7 20

1.5

28

20

R1

20

ax m

P1 P2 P3 P4

Microcellular rubber 10*3 glued at installation 1* Ø10 borehole (outlet)

38

10

=

=

10

Medium of the filter Material: St. 37 / round wire Ø 0.28 galvanized / mesh width 6-8 mm Frame and screen St. 37 not galvanized Material: V4A 1.4571 / round wire Ø 0.28 / mesh width 6-8 mm Frame and screen like above (marine) Material: Monell CuNi 2.4360 / round wire Ø 0.28 / mesh width 6-8 mm Frame and screen V4A 1.4571 Plastic PP / mesh width 6-8 mm Frame V4A 1.4571

Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DSG29144(ohne Cosimat).doc

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Cummins Generator Technologies Germany GmbH Bunsenstraße 17 85053 Ingolstadt, Germany Phone: +49(0)841-792-0 Fax: +49(0)841-792-250 e-mail: [email protected] www.cumminsgeneratortechnologies.com Cummins Generator Technologies Germany GmbH Dreieich Office Benzstraße 47-49 63303 Dreieich, Germany Phone: +49(0)6103-5039-0 Fax: +49(0)6103-5039-40 e-mail: [email protected] www.cumminsgeneratortechnolgies.com

Cummins Generator Technologies Germany GmbH POD-geno-AvK-eng-DSG29144(ohne Cosimat).doc

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Regulator Description

INSTRUCTION MANUAL FOR

DIGITAL EXCITATION CONTROL SYSTEM DECS-100

Publication: 9287500991 Revision: H 05/08

INTRODUCTION This instruction manual provides information about the operation and installation of the DECS-100 Digital Excitation Control System. To accomplish this, the following information is provided: x

General Information and Specifications

x

Controls and Indicators

x

Functional Description

x

Installation

x

Maintenance and Troubleshooting

WARNING! To avoid personal injury or equipment damage, only qualified personnel should perform the procedures in this manual. Lethal voltage is present at the rear panel when the unit is energized. Rear panel connections should be made only when the unit id de-energized.

CAUTION The Manual mode excitation level must be evaluated prior to enabling this feature. If the level of excitation current is inappropriate for the generator, severe damage to the generator may occur. Improper PID numbers will result in poor system performance or system damage. When applying operating power for programming purposes, observe the precautions called out in Section 4, Installation, Preliminary Setup. When programming the DECS-100 without the generator spinning, the connections to DECS-100 terminals F+ and F– should be removed. Before uploading a settings file, remove operating power from the DECS-100, disconnect the field wiring from terminals F+ and F–, and re-apply operating power to the DECS-100.

NOTE Be sure that the DECS-100 is hard-wired to earth ground with no smaller than 12 AWG copper wire attached to the ground terminal on the rear of the unit case. When the DECS-100 is configured in a system with other devices, it is recommended to use a separate lead to the ground bus from each unit.

9287500990 Rev H

DECS-100 Introduction

i

First Printing: March 2001 Printed in USA © 2008 Basler Electric, Highland Illinois 62249 USA All Rights Reserved May 2008

CONFIDENTIAL INFORMATION of Basler Electric, Highland Illinois, USA. It is loaned for confidential use, subject to return on request, and with the mutual understanding that it will not be used in any manner detrimental to the interest of Basler Electric.

It is not the intention of this manual to cover all details and variations in equipment, nor does this manual provide data for every possible contingency regarding installation or operation. The availability and design of all features and options are subject to modification without notice. Should further information be required, contact Basler Electric.

BASLER ELECTRIC ROUTE 143, BOX 269 HIGHLAND IL 62249 USA http://www.basler.com, [email protected] PHONE +1 618.654.2341 FAX +1 618.654.2351 ii

DECS-100 Introduction

9287500990 Rev H

REVISION HISTORY The following information provides a historical summary of the changes made to the DECS-100 hardware, firmware, and software. The corresponding revisions made to this instruction manual (9287500991) are also summarized. Revisions are listed in chronological order. Hardware Version and Date E, 01/01 F, 05/01 G, 10/01 H, 02/02

O P, 08/06

x x x x x x x x x x x x x x

Q R, 04/07 S, 05/07 T, 07/07 U, 01/08 V, 03/08

x x x x x x

J, 07/02 K, 02/03 L, 03/03 M, 01/04 N, 05/05

Firmware Version and Date 1.09.XX, 01/01 1.11.XX, 07/01

1.12.XX, 03/02 2.13.XX, 07/07

2.14.XX, 03/08 BESTCOMS for Windows® OS Version and Date 1.02.XX, 02/01 1.03.XX, 08/01

1.04.XX, 04/02 9287500991 Rev H

Change Initial release Deepened potting shell Began supplying mounting screws SIL-PADS were added between power components and the heat sinks Added manufacturing origin to the rear label Revised EEPROM Replaced transistor Q8B1 with an improved part Incremental improvements to firmware and BESTCOMS Improved flash memory retention Redesigned current transformer Added front panel Underexcitation Limiting indicator Enhanced EMI/RFI immunity Version letter O not used Updated CD-ROM supplied with unit to include English and French language instruction manuals Version letter Q not used Resolved UEL issue with firmware modification Provided German language manual on CD-ROM supplied with DECS-100 Released firmware version 2.13.XX Improved power amplifier circuitry with more robust components Added Setpoint Auto Save feature

Change x Initial release x Enabled the protection function during the first 5 seconds of operation x Modified the OEL setpoint scale factor to be compatible with BESTCOMS version 1.03.XX x Added the scale factor for per-unit gain x Established minimum voltage regulation at 30% of nominal sensing voltage x Added register to detect CT type x Added underexcitation limiting x Added takeover-style excitation limiting x Added bus voltage matching provisions x Added Setpoint Auto Save setting

Change x Initial Release x Changed OEL scale from 100 to 1,000 to match the change in firmware version 1.11.01 x Changed OEL default setting from 1 to 15 x Changed the default for all protection functions to enabled x Add support for French regional settings x Made BESTCOMS compatible with older firmware versions x Added support for all regional settings DECS-100 Introduction

iii

BESTCOMS for Windows® OS Version and Date

1.05.XX, 05/05

1.06.XX, 11/07 1.07.XX, 03/08 BESTCOMS for Palm® OS Version and Date 1.01.XX, 01/01 1.02.XX, 08/01

1.03.XX, 04/02 NOTE

Manual Revision and Date —, 03/01 A, 03/01

B, 08/01

C, 05/02

D, 01/03

E, 03/04

iv

Change x Enabled reading of secondary CT value for units with firmware version 1.12.01 and higher x Simplified the Analysis screen x Added feature to calculate and send voltage matching reference for different generator and bus PT ratios x Changed minimum Ki setpoint from 0 to 0.01 x Added underexcitation limiting capability x Added ability to select either summing point or takeover style OEL x Added provisions for bus voltage matching x Added compatibility with Microsoft® Vista to BESTCOMS x Added Setpoint Auto Save setting.

x x x x x x x

Change Initial Release Added a Check for New Version button to the Contact Basler screen Added a date/time stamp to the “Save to File” names Added version checking Added password protection Improved version checking function BESTCOMS for Palm OS is compatible only with firmware versions 1.12.XX and earlier

Change x Initial release x In Section 5, BESTCOMS Software for the Windows® Operating System and Section 6, BESTCOMS Software for the Palm OS® Platform, Step 2 of Installing BESTCOMS was revised to reflect the addition of an auto-start utility for the DECS-100 CD-ROM x Added Embedded Software subsection to Section 5, BESTCOMS Software for the Windows® Operating System x Corrected various minor errors throughout manual x Revised the torque specification for the mounting screws supplied with unit x In Section 5, BESTCOMS Software for the Windows® Operating System and Section 6, BESTCOMS Software for the Palm® OS Platform, text and illustrations were revised to accommodate software enhancements x Revised Voltage Matching Time Adjustment Range from 0 to 300 seconds to 1 to 300 seconds throughout manual x Corrected figure number references in Sections 5 and 6 x Added Operating Power Considerations During DECS-100 Programming to Section 4, Installation, Preliminary Setup x Added caution box regarding application of operating power during DECS100 programming to Section 5, BESTCOMS for Windows® OS and Section 6, BESTCOMS for Palm OS® x Corrected CT ratio setting range stated in Section 5

DECS-100 Introduction

9287500991 Rev H

Manual Revision and Date F, 05/05

G, 03/07

H, 05/08

9287500991 Rev H

x x x x x x x x x x x x x

Change Added material covering added UEL capability Revised all drawings to show new front panel with UEL indicator Updated all illustrations of rear panel to show revised CT Added discussion of summing point and takeover style OEL limiting Revised voltage matching description to cover Maintain and Revert modes Corrected the hole drilling diameter shown in Figure 4-2 Added illustration/description for using the ICRM-7 with the DECS-100 Removed Section 6, BESTCOMS Software for the Palm® OS Platform and moved Maintenance and Troubleshooting to Section 6 Added troubleshooting procedure for a UEL annunciation Corrected illustration and descriptions of BESTCOMS Metering, Operation and Alarms screen, Operation tab Removed expired patent information Added DNV compliance statement to manual specifications Added description of BESTCOMS Setpoint Auto Save feature

DECS-100 Introduction

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DECS-100 Introduction

9287500991 Rev H

CONTENTS A detailed table of contents is provided at the start of each manual section. The manual sections are ordered as follows.

Section 1

General Information .................................................................................................. 1-1

Section 2

Human-Machine Interface......................................................................................... 2-1

Section 3

Functional Description .............................................................................................. 3-1

Section 4

Installation ................................................................................................................. 4-1

Section 5

BESTCOMS Software............................................................................................... 5-1

Section 6

Maintenance and Troubleshooting............................................................................ 6-1

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DECS-100 Introduction

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SECTION 1 x GENERAL INFORMATION TABLE OF CONTENTS SECTION 1 x GENERAL INFORMATION ................................................................................................ 1-1 INTRODUCTION.................................................................................................................................... 1-1 FEATURES ............................................................................................................................................ 1-1 MODEL AND STYLE NUMBER............................................................................................................. 1-1 Style Number...................................................................................................................................... 1-1 SPECIFICATIONS ................................................................................................................................. 1-2 Operating Power ................................................................................................................................ 1-2 Generator Voltage Sensing ................................................................................................................ 1-2 Generator Current Sensing ................................................................................................................ 1-2 Bus Voltage Sensing (Optional) ......................................................................................................... 1-2 Accessory Input .................................................................................................................................. 1-3 Communication Port........................................................................................................................... 1-3 Contact Input Circuits ......................................................................................................................... 1-3 Common Alarm Output....................................................................................................................... 1-3 Field Output ........................................................................................................................................ 1-3 AVR Operating Mode ......................................................................................................................... 1-3 FCR (Manual) Operating Mode .......................................................................................................... 1-4 Var Operating Mode (Optional) .......................................................................................................... 1-4 PF Operating Mode (Optional) ........................................................................................................... 1-4 Parallel Compensation ....................................................................................................................... 1-4 Field Overvoltage Protection .............................................................................................................. 1-4 Generator Overvoltage Protection ..................................................................................................... 1-4 Overexcitation Limiter......................................................................................................................... 1-5 Underexcitation Limiter....................................................................................................................... 1-5 Soft Start Function (AVR Mode Only) ................................................................................................ 1-5 Voltage Matching................................................................................................................................ 1-5 Metering (BESTCOMS)...................................................................................................................... 1-5 Environment ....................................................................................................................................... 1-6 Type Tests.......................................................................................................................................... 1-6 Physical .............................................................................................................................................. 1-6 Agency Recognition ........................................................................................................................... 1-6 CE Compliance .................................................................................................................................. 1-6 Figures Figure 1-1. DECS-100 Style Chart ............................................................................................................ 1-1 Figure 1-2. Typical V/Hz Curves................................................................................................................ 1-4

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DECS-100 General Information

9287500991 Rev H

SECTION 1 x GENERAL INFORMATION INTRODUCTION The Basler Digital Excitation Control System (DECS-100) is an electronic, solid-state, microprocessor based control device. The DECS-100 regulates the output voltage of a brushless, ac generator by controlling the current into the generator exciter field. Input power to the DECS-100 can be from a multipole, high-frequency, permanent magnet generator (PMG) or from the generator output when used as a conventional, shunt-excited, excitation system. The DECS-100 is supplied in an encapsulated package designed for behind-the-panel mounting. The DECS-100 is held in place by thread-forming screws that thread into its plastic shell. Front panel indicators (LEDs) annunciate DECS-100 status and system conditions. DECS-100 connections are made through quarter-inch, quick-connect terminals on the rear panel. A 9-pin DB-9 type connector on the rear panel provides communication between the DECS-100 and an IBM compatible PC.

FEATURES DECS-100 units have the following features and capabilities: x x x x x x x x x x x x x x x

Four control modes: automatic voltage regulation (AVR), manual or field current regulation (FCR), power factor (PF) regulation, and reactive power (var) regulation. Programmable stability settings. Soft start and voltage buildup control with an adjustable ramp in AVR control mode. Overexcitation limiting (OEL) and underexcitation limiting (UEL) in AVR, Var, and PF control modes. Underfrequency (volts/hertz) regulation. Three-phase or single-phase generator voltage (rms) sensing/regulation in AVR mode. Single-phase bus voltage (rms) sensing. Single-phase generator current sensing for metering and regulation purposes. Field current and field voltage sensing. One analog input for proportional remote control of the setpoint. Five contact sensing inputs for system interface. One common output relay for alarm indication and trip functions. Three protection functions: field overvoltage, generator overvoltage, and loss of sensing. Generator paralleling with reactive droop compensation and reactive differential compensation. Rear RS-232 communication port for personal computer communication using BESTCOMS Windows® based software for fast, user-friendly, setup and control.

MODEL AND STYLE NUMBER The model number, together with the style number, describe the options included in a specific device, and appear on a label affixed to the rear panel. Upon receipt of a DECS-100, be sure to check the style number against the requisition and the packing list to ensure that they agree. Style Number DECS-100 electrical characteristics and operational features are defined by a combination of letters and numbers that make up the style number. The DECS-100 style number chart is shown in Figure 1-1.

Figure 1-1. DECS-100 Style Chart 9287500991 Rev H

DECS-100 General Information

1-1

Style Number Example For example, a DECS-100 with a style number of A15 would have the following characteristics and operating features. A ------- No var or power factor control 1-------- Voltage matching 5-------- 5 ampere current sensing

SPECIFICATIONS DECS-100 specifications and qualifications are listed in the following paragraphs. Operating Power Refer to Section 4, Installation for special requirements concerning the application of operating power during DECS-100 programming and the application of station power. Voltage: 88 to 250 Vac, single-phase or three-phase (L-L) Frequency: 50 to 400 Hz Burden: 650 VA Voltage Buildup: t6 Vac Terminals: 3, 4, 5 Generator Voltage Sensing Type: Burden: Terminals:

1-Phase/3-Phase, 4 ranges