CAUTION

The information contained in this book is intended to

assist operating personnel by providing information on
the general characteristics of the purchased equipment.
IT DOES NOT relieve the user of the responsibility of using
accepted engineering practices in the installation,
operation and maintenance of this equipment.

Contents

1. Construction of Brushless A.C Generator (Safety Notes)

1.1 Component
1.2 General
1.3 Composition

2. Excitation System (Operation)

2.1 Mode of Operation (SPRESY 15)
2.2 Operation (SPRESY 15)
2.3 Maintenance (SPRESY 15)
2.4 Mode of Operation (6 GA 2491)
2.5 Operation (6 GA 2491)
2.6 Maintenance (6 GA 2491)

15

3. Maintenance
3.1 Installation & Inspection Check List
3.2 Flange-Type Sleeve Bearing (for ring lubrication system)
3.3 Flange-Type Sleeve Bearing (forced lubrication system)
3.4 Rolling-Contact Bearings (series 02 and 03)
3.5 Coupling A-Type (single-bearing generators with flanged shaft and one-part fan wheel)
3.6 Coupling B-Type (single-bearing generators with flanged shaft)
3.7 Coupling (double bearing generator)
3.8 Air Filters
3.9 Terminal Box
3.10 Disassembly of A.C. Generator (Fig. 39 and 40)
3.11 Cooler
3.12 Cooling-Water Failure Emergency Operation

25

4. Trouble Shooting
4.1 Excitation Part for SPRESY 15
4.2 Excitation Part for 6 GA 2491
4.3 Main Machines and Exciters (HF. 5 and 6)
4.4 Bearing Part
4.5 Operating Procedure & Check Sheet for Trouble Shooting

46

01

Construction of Brushless A.C Generator

Safety Notes
The warnings
NOTE

NOTE

DANGER, WARNING, CAUTION, NOTICE,

are used to draw the users attention different

This warning is used when an operation, procedure, or

delicate installation requires clarification.

points:
DANGER
This warning is used when an operation, procedure, or
use may cause personal injury or loss of life.
WARNING
This Warning is used when an operation, procedure, or
use may cause a latently dangerous state of personal
injury or loss of life.
CAUTION
This warning is used when an operation, procedure, or
use may cause damage to or destruction of equipment
and a slight or serious injury.

1.1 Component
The brushless A.C. generators, as shown in Figs. 8. 9. 10
and 11, (drip-proof type, totally-enclosed internal-cooling
type) are composed of
a synchronous generator
an A.C. exciter
a Rotary rectifier
static excitation devices.
The brushless generator, as shown in Figs. 8, 9, 10 and
11, has the exciter and the rotary rectifier mounted on
the generator's rotor shaft. The three-phase output of the

NOTICE
This warning is used when an operation, procedure, or
use may cause damage to or destruction of equipment.

2 << Operating Instructions Synchronous Generator

A.C. exciter is rectified to D.C. by means of the rotary

rectifier, thus enabling the exciting current to be supplied,
not through sliding parts, but directly to the field coil of
the generator.

Operating Instructions
Synchronous Generator

Fig. 1 Single line diagram for brushless generator

Unless otherwise stated, the rated output for continuous

operation applies to a frequency of 50 Hz, a cooling-air
temperature of 40

and a site altitude of up to 1000 m

above sea level.

3) Degree of protection
The DIN 40050 or IEC 34-5 degree of protection of basic
design machines is IP 23. Such machines are suitable for
operation indoors and may be provided with a built-in
filter box or with pipe connections.

1.2 General
1) Type definition

Closed-circuit cooled machines comply with degree of

protection IP 54.
The degree of protection of the machine supplied is
shown in the dimension drawing.

The supply scope of the machine designs a vailable is

determined entirely by the data given in the catalogs or
offers. The machines of basic design are open-circuit

4) Type of construction

cooled, brushless, low-voltage, synchronous machines

The machines are normally provided with two bearings

with top-mounted excitation control unit.

(DIN 42950 types of construction B3 or B20) or with one

bearing (DIN 42950 types of construction B2 or B16).

The machines have a shaft-mounted exciter on the

The type of construction of the machine supplied is

inboard side of the non-drive endshield.

shown in the dimension drawing.

The three-phase AC they generate is rectified and fed to

the rotor winding of the main machine.

5) Cooling and ventilation

The excitation current required for the shaft-mounted

The basic design machines use self-ventilation by a shaft-

exciter is provided by the main machine via an excitation

mounted internal fan at the AS-end.

control unit placed in the top mounted housing, and via a

Cooling air enters the top housing (at the BS-end) and

thyristor voltage regulator.

cools the excitation control unit and, subsequently, the

windings and core packs of the exciter and of the main

For further information, see the supplementary

machine before leaving the top housing at the BS-end.

instructions entitled THYRIPART excitation system on

pages 15-24.

On machines provided with air filters at the air inlet,

Depending on the application, the machines may also be

the loading condition of the filter should be monitored.

designed in accordance with the type variant defined in

the table below.
Table 1-1. Type definition
Type

HFJ 5, 6

HFC 5, 6
HSR

Type of construction

In machines having closed-circuit cooling, the air-to-water

cooler is placed transversely in the top-mounted box in
transverse arrangement, in front of the excitation control
unit.

Machines with closed-circuit cooling and air-to-

The primary cooling air circulated by the internal fan is re-

water cooler with provisions for emergency

cooled in the cooler and passed through the excitation

operation in case of cooling water failure

control unit, the exciter, and the main machine.

Machines with open circuit cooling and air-to-air

High voltage machines with open or closed circuit

Given the necessary provisions, the machine can be

cooling

adapted for emergency operation with open-circuit

cooling in case of cooling water failure. See pages 44-45.

2) Specification & regulation

The machines comply with the applicable DIN standards
and with the requirements of VDE 0530.
They may have been adapted to different classification
requirements and foreign standards and regulations.

6) Connecting up
Check the system voltage against the data given on the
rating plate. Select the size of the supply cables to match
the particular current rating.

Instruction Manual

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01

Construction of Brushless A.C Generator

Connect the machines in accordance with the diagram in

the working drawing.

Dry new windings have insulation resistance values

between 100

and 2000

or higher.

If the insulation resistance value is in the region of the

Before closing the terminal box, check to see that

minimum value, dampress and or dirt could be the cause.

If the insulation resistance value falls below this minimum

Its interior is clean and free from any cable chippings

figure, the cause must be established and the winding

All terminal screws or bolts are tight

dried.

The minimum clearances in air are maintained

(>10 mm for 500 V, >14 mm for 1 kV and >60 mm

In case of drying by warm air oven.

for 6 kV; check for any projecting wire ends)

Remove bearing housings

Entry openings not in use are closed off by firmly

Remove rotor

screwed-in plugs

Remove diode varistor is excitation equipment part

For maintaining the particular degree of protection all

sealing surfaces of the terminal box are in order.

Bake in oven at temperatures per below table.

The surfaces of metal-to-metal sealing joints must be

The heat should be applied slowly so the desired

cleaned and thinly regreased.

temperature will not be obtained in less than six hours.

Insulation resistance should be measured before the heat

Before starting a machine and during operation make

is applied, and every six to eight hours thereafter.

sure that all relevant safety regulations are complied with.

Table 1-3. Insulation Drying Temperatures*

7) Insulation testing
DANGER
Hazardous voltage
Will cause death, serious injury, electrocution or property
damage.
Disconnect all power before working on this equipment.

Class B

Class F

Class H

200 F
94 C

245 F*
118 C

275 F*
135 C

* Class F and H insulated units should be baked at 70% specified

temperature (to avoid steam inside winding) for about six hours,
before temperature is raised to drying temperature.

The insulation resistance for clean windings is largely

dependent on temperature: for each 10K rise in
Before commissioning and after long periods of storage or

temperature it falls by half, i.e. with a temperature rise of

standstill the insulation resistance of the windings to the

50K (e.g. from 25

frame must be measured with D.C. voltage.

initial value.

to 75

) it falls to about 1/30 of the

Do not discontinue measurement before the final

resistance value is indicated(with high-voltage machines,

During operation the insulation resistance of the windings

this process may take up to 1minute).

may decrease as result of environmental and operating

The limit values for minimum insulation resistance and

conditions.

critical insulation resistance (for measurement at a

The critical value of the insulation resistance at a winding

winding temperature of 25

temperature of 25

) and for measuring voltage

can be calculated depending on the

can be derived from the following table depending on the

rated voltage by multiplying the latter (kV) by the specific

rated voltage for the machine.

critical resistance value in the table (

Table 1-2. Insulation testing

For example: critical resistance for rated voltage

Limit values at rated voltage

Measuring voltage

/kV).

Rated voltage
< 2 kV

Rated voltage
> 2 kV

500 V DC
(min.100 V DC)

500 V DC
(max.1000 V DC)

Minimum insulation
resistance with new machine.
Cleaned of repaired windings

/kV = 0.33

If the measured insulation resistance value is above the

calculated critical figure during operation, the machine
can still operate further.
When the measured value reaches or falls below this

100

10

660 V: 0.66 kV x 0.5

critical insulation resistance figure, however, the windings

must either be dried, or the rotor must be removed and

Critical specific insulation

resistance after long
period of operation

0.5

4 << Operating Instructions Synchronous Generator

/kV

/kV

the windings thoroughly cleaned and dried.

Operating Instructions
Synchronous Generator

If the measured value approaches the critical value, the

11) Storage

resistance should subsequently be checked at

appropriate short intervals.

WARNING

Insulation resistance measurements on low-voltage

machines with a measuring voltage of 1000 V are only
permissible if the insulation resistance has previously
been measured with a measuring voltage of a maximum
of 500 V and has not fallen below the permitted values.

Can cause severs injury or property damage.

When lifting generator.
1. Lift only at designated locations.
2. Use spreader for lifting.
3. Apply tension gradually to slings.
4. Do not jerk or attempt to move unit suddenly.
5. Do not use cover lugs when lifting.

The location for storage should be dry and clean.

8) Noise emission
The noise level of the generator will not exceed that
specified in Part 9. VDE 0530 (1981).

There should be no fever min that could attack the

winding.
The machined surfaces (coupling part, foots part, etc).
are coated with rust-resistant grease.
If the coating is broken, immediately remover the rust or

9) Vibration stability
Reciprocating engines used as prime mover impress
vibrations on the alternator because of the pulsating
torque output.
Permissible vibration stress measured at the bearing is:

moisture and recoat with grease for rust prevention.

If the machine is to be stored for some time, apply all
openings with waterproof paper, wooden, or metallic
covers.
It is necessary, to protect from the machine wind and rain

< 10 Hz

vibration amplitue

< 0.40 mm-peak

10-100 Hz

vibration velocity

Veff

< 18 mm/s-rms

> 100 Hz

acceleration

< 1.6 g

Please inquire if a higher vibration stress level is expected.

during trans-portation and storage and to select less

humid place for storage.
For storage for a long-term or in the rainy season, it is
best to insert heaters to remove moisture or prevent its
condensation.
To keep the coil dry, maintain the coil temperature
several degrees above room temperature by arranging

10) Transport

heaters appropriately under the machine part to warm

WARNING

Improper handling can cause severs injury or property

damage.
When lifting generator.
1. Lift only at designated locations.
2. Use spreader for lifting.
3. Apply tension gradually to slings.
4. Do not jerk or attempt to move unit suddenly.
5. Do not use cover lugs when lifting.

The rotor of machines with cylindrical roller bearings,

angular-contact ball bearings, or double sleeve bearing
are locked in position for transport by a shaft block to
protect the bearings.
Do not remove this block until the transmission element

the coils.
For long time storage, a space heater is placed inside the
generator. Its specification is described in the generator
final specification and on the nameplate attached to the
generator.

12) Installation
NOTE
Experience has shown that any base mounted assemblies
of generator and driven units temporarily aligned at the
factory, no matter how rugged or deep in section may
twist during shipment.
Therefore, alignment must be checked after mounting.

is fitted.
Should the machine have to be transported after the

The lubrication measures for normal bearings to be

transmission element is fitted, other suitable measures

carried out before or during erection of the machines are

have to be taken.

specified in the instructions "Rolling Contact Bearings and

If the machine is not put into service immediately after

Sleeve Bearings" on pages from 27-36.

arrival, store it in a dry, vibration-free room.

Instruction Manual

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01

Construction of Brushless A.C Generator

Install the machines so that the cooling air has free

14) Maintenance

access and can escape unobstructed.

Before starting any work on a machine, make sure that it

Warm exhaust air must not be drawn in again.

has been disconnected from the power supply and that

unintentional starting is safely prevented.

Louver openings must face downwards to maintain the

particular degree protection.

Clean the cooling air passages at regular intervals,

Remove the shaft block (where applicable).

matching the degree of pollution and using oil-free

Follow the instructions attached to the shaft extension or

compressed air, for example.

shown in the terminal box.

The inside of totally-enclosed fan-cooled machines need
The rotors are normally balanced dynamically by means

only be cleaned during normal overhauls.

of a half feather key placed in the shaft extension.

Align the machines carefully and accurately balance the

If dust or moisture has penetrated into the terminal

elements to be fitted on the shaft to ensure smooth and

compartment, it should be carefully cleaned and dried,

vibration-free running.

in particular the surfaces of the insulating parts.

Check the seals and eliminate the leak.

Place shims under the feet of the machines if necessary

to prevent them from being stressed mechanically.

Before forcing off a part, replace two upper fixing screws

Transmission elements may be fitted and removed only

with longer screws or threaded bolts to support the part

by means of a suitable tool.

after forcing it out of its central facility.

The feather keys in the shaft extensions are only secured

to prevent them from falling out during shipment.
A machine must not be commissioned without its
transmission element having been fitted.

15) Inspection
The first inspection should be carried out after
approximately 500 hours.
The rate of fouling should be assessed and appropriate

13) Operation

periods for cleaning the cooling air ducts decided upon.

WARNING

Do not operate equipment beyond design limitations.

Can cause personal injury or damage to equipment.
Operate in accordance with instructions in the manual
and nameplate ratings.

The following checks should also be carried out:

Running smoothness of machine satisfactory
Rotor alignment within tolerances
No subsidence or cracks in the foundation
All fixing bolts of mechanical and electrical joints tight
Insulation resistance of windings satisfactory

NOTICE
In case of cooling system of IP44 (air to water), check the
flow of cooling water for sure before starting.
Internal temprature rise may cause fatal damage to the
generator.

(compare with previous reading and record)

No bridging of any bearing insulation
Any excessive deviations or changes ascertained during
the checks must be corrected immediately.
Damaged or used locked elements from released bolted
joints must be renewed.

NOTICE
Before starting, check if the bearing oil is filled with or, not
to the sufficient oil level.

The basic intervals between inspections are approximately 4000 hours, 1000 switching operations or 1 year for
intermittent operation and approximately 16,000 hours

Covers fitted to prevent access to rotating and current

or 2 years for continuous operation, depanding on which

carrying parts or to correct the air flow for better cooling

occurs first.

must not be open in operation.

The cleaning of all parts becoming fouled by the flow of

If machine application is abnorma (high temperature,

cooling air depends on the intervals decided after the first

extreme vibration, etc.) consult HHi for special

inspection according to the rate of fouling which occurs

instructions.

locally.

6 << Operating Instructions Synchronous Generator

Operating Instructions
Synchronous Generator

Cleaning should be carried out with dry compressed air.

2) Rotor and windings

Information on oil changes, regreasing, etc. is given on

The shaft for machines construction type B3 and B20

the lubrication instruction plate on the machine or in the

is designed with a normal cylindrical shaft extension for

supplementary instructions for bearings.

two bearings. In the case of types B2 and B16 the shaft

The checks stated for the first inspection after 500 hours

is fitted with a flange.

should be performed during these inspections also.

The rotor core of the main machine is mounted on the

When a machine is dismantled the following checks

shaft, tensioned axially, and supports the field and damper

should be made:

windings. The damper winding bars lie in the slots of the

Slot wedges in stator and rotor cores tight

rotor core and are welded to the rings.

Windings, connection leads, and insulating parts in

The rotor core of the exciter is mounted on the shaft and

satisfactory condition with no discoloration

supports the three-phase field winding.

The rectifier supporting wheel is mounted on the shaft

After reassembly, again follow the instructions given for

between the two laminated cores.

installation.

The rotor is balanced dynamically.

16) Spare parts

3) AC exciter

The classification societies normally specify sets of spares

The AC exciter is composed for revolving-armature type,

as follows:

three-phase, synchronous generators.

In revolving-armature type generators, unlike ordinary

Table 1-4. Spare parts

Spares

ones, the stator and rotor are in reverse relation.

Classification society
KR ABS BV GL LRS NV RINA NK

1 set of bearing shells for

sleeve bearings with oil
ring
1 complete rectifier
1 electronic regulator

The armature is installed at the shaft end on the nonconnection side where AC power is generated, and the
output of the static excitation device for control is
connected to the field winding installed on the fixed side
as shown in Fig. 2.
Fig. 2 Single line diagram for AC exciter

Independant of the classification societies requirements,

we recommend the following sets of spares be ordered
with the alternators:
1 set of bearings or bearingshells for sleeve bearing
1 set of rotating rectifiers
1 set of rectifiers for the constant-voltage unit
1 regulator (AVR)

1.3 Composition
4) Rotating rectifier
1) Stator frame and winding

The rotating rectifier is a silicon rectifier which is

The stator frame is of welded design.

connected so as to compose a three-phase full-wave

The stator core is centred in the frame and locked against

rectification circuit as shown in Fig. 3 and is mounted on

rotation and shifting.

the rotor shaft of generator in Fig. 8-1.

The stator winding is of a two-layer coil design with

insulation class F.

The mounting screws are between 4.5 Nm and 5.5 Nm

This insulation is made in a special way and is comprised

The contact screws are between 2.5 Nm and 3.5 Nm

of integrated-mica & enamel coated insulating material

impregnated with cast resin.
It is characterized by high dielectric strength, resistance
to moisture, aggressive gases and vapours, as well as

CAUTION
The rotating diode fastening screws must be tightened to
the recommended torque.

rigidity and long life.

Instruction Manual

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01

Construction of Brushless A.C Generator

Fig. 3 Single line diagram for rotating rectifier

It is a one-way ventilating system which takes in air from

the opposite side of the prime mover and lets out exhaust
air at the prime mover's side.
We have taken into consideration that the engine's oil
vapor should not be sucked into the machine.

9) End shield AS/BS

Both end shields are designed as flat plates and can take
either a bearing or a shaft extension in accordance with
the particular type of machine construction.
The exciter yoke ring in which the exciter poles are bolted
in regular distribution, is welded to the BS-end shield.

5) Excitation system

10) Rotor locking device

The combination of an excitation unit with a thyrist or

The following instructions supplementing and modifying

voltage regulator is called a THYRIPART-excitation system.

the basic operating instructions apply to single bearing

The excitation unit supplies a load-dependent field current

generators of type of construction B2 or B16 which are

slightly higher than would be required for producing the

coupled with diesel engines or turbines.

rated voltage.

See the instruction manual on pages 37-38.

The regulator variably reduces the field current as

Fig. 4 Rotor locking device

necessary to obtain constant alternator voltage.

This method of load-dependent excitation (compounding)
results in excellent dynamic response to load switching
applications and short-circuits.
A block diagram is shown in Figs. 14, 15, 19 & 20.

6) Shaft
Concerning the generator shaft, the ship's classification
certified forged steel should be applied and designed with
ample strength for coupling with the prime mover.

7) Bearing

End shield AS
Retaining ring half
Shaft supporting ring

Flanged shaft
Fixing screw for 1
Fixing screw for 3

Depending on the design and the operating conditions

specified in the order, the machines are fitted with
grease-lubricated rolling-contact bearings or with sleeve
bearings with or without forced-oil lubrication.

11) Insulation for the prevention of shaft current

(high voltage and large machines)

For a full description and special instructions, reference

should be made to the supplementary instructions.

8) Cooling fan

NOTE
Insulated Bearing
Any connection to this bearing must be insulated from it
to prevent bearing current.

To let the required amount of cooling air pass through, a

fan of either cast iron or welded steel plate construction

To prevent the shaft current caused by the unbalance of

is provided.

magnetic resistance of magnetic circuits, the insulator is

Concerning the site of its installation, in either case, the

provided at the end shield BS side as shown in Fig. 5.

for it is to be arranged on the prime mover's side of the

The shaft voltage is a high-frequency voltage of usually

generator.

1 volt or less and rarely several volts.

8 << Operating Instructions Synchronous Generator

Operating Instructions
Synchronous Generator

When a shaft current flows, by this voltage the shaft and

13) Space heater

journal part are tarnished. In the worst condition, sparking

results in minute black spots.

DANGER

There is a possibility that the oil film is broken locally,

developing burn-out trouble.
When disassembling or assembling, be sure to measure

Hazardous voltage
Will cause death, serious injury, electrocution or property
damage.
Disconnect all power before working on this equipment.

the insulation resistance.

The value of 1 to 3

In order to prevent the accumulation of moisture and

will be satisfactory.

It is generally said that shaft voltage for bearings is limited

as follows.
<300 mV

Harmless.

500 to 1,000 mV A detrimental shaft current may

possibly flow.
>1,000 mV

Bearings may be damaged in a week

condensation while the generator is idle, space heaters

are provided within the stator frame.
The space heaters can be easily removed from outside
the enclosure.
The heater is comprised of stainless-sheathed nichrome,
filled with insulators in the sheath and is U-shaped as
shown in Fig. 6.
Fig. 6 Space heater

to a year
(unless insulation is provided).
Fig. 5 Insulation for the preventation of shaft current

14) Air/water cooler

If required, HFC6. and HFC5. alternators can be supplied
with a top-fitted air/water cooler as special requirement.
The cooler can be used for fresh water or sea water and
can be of the double-tube type.
The type designation for the alternators is changed from
HFC to HFJ.
Due to the closed-circuit cooling system the degree of
protection has been upgraded from IP 23 to IP 44 and
IP 54.

12) Thermometer
For checking the bearing temperature, a mercury
thermometer is provided.
U-shaped as shown in Fig. 6.

The electrical version of the alternator remains unchanged.

The alternators HFJ can easily be converted for emergency
operation as an open-circuit aircooled machine if the
coolant system or the cooling element fails.

Instruction Manual

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01

Construction of Brushless A.C Generator

In this case the degree of protection is IP 23 with the rated

15) Terminal box

output as shown on pages 44-45.

DANGER

Please provide the following information with any inquiry:

Alternate rated output
Classification society

Hazardous voltage
Will cause death, serious injury, electrocution or property
damage.
Disconnect all power before working on this equipment.

Coolant temperature (air)

Cooling water inlet temperature
Fresh water or sea water

Cable entry to the 3 main connections, (U.V.W.) and to the

2 field terminals +F1, -F2 can be from the left or right, as
required.
The cable entry plates are supplied undrilled or drilled
with cable gland as required.
See Fig. 7.

Fig. 7 Internal arrangement for terminal box

( HF. 6 type )

10 << Operating Instructions Synchronous Generator

( HF. 5 type )

Operating Instructions
Synchronous Generator

Fig. 8 Sectional drawing for HF. 5 type generator (single sleeve bearing)

HFJ 5 (air to water cooling)

HFC 5 (air to air cooling)

Stator and stator windings assembly
Rotor and windings assembly
A.C exciter assembly
Rectifier assembly (Fig. 8-1)
Excitation equipment
Shaft
Bearing
Cooling fan
End shield AS/BS
Rotor lockage device
Insulation for prevention of shaft current (Fig. 5)
Thermometer
Space heater
Cooler
Terminal box

Fig. 8-1 Rectifier assembly

Varistor module
Hub

Connector rings
Rectifier module

Instruction Manual

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11

01

Construction of Brushless A.C Generator

Fig. 9 Sectional drawing for HF. 5 type generator (double sleeve bearing)

HFJ 5 (air to water cooling)

HFC 5 (air to air cooling)

Stator and stator windings assembly
Rotor and windings assembly
AC exciter assembly
Rectifier assembly (Fig. 9-1)
Excitation equipment
Shaft
Bearing
Cooling fan
End shield AS/BS
Terminal box
Insulation for prevention of shaft current (Fig. 5)
Thermometer
Space heater
Cooler

Fig. 9-1 Rectifier assembly

Varistor module
Hub

12 << Operating Instructions Synchronous Generator

Connector rings
Rectifier module

Operating Instructions
Synchronous Generator

Fig. 10 Sectional drawing for HF. 6 type generator (single sleeve bearing)

HFJ 6 (air to water cooling)

HFC 6 (air to air cooling)

Stator frame and stator windings assembly
Rotor and windings assembly
AC exciter assembly
Rectifier assembly (Fig. 10-1)
Excitation equipment
Shaft
Bearing
Cooling fan
End shield AS/BS
Rotor lockage device
Insulation for prevention of shaft current (Fig. 5)
Thermometer
Space heater
Cooler
Terminal box

Fig. 10-1 Rectifier assembly

Varistor module
Hub

Connector rings
Rectifier module

Instruction Manual

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13

01

Construction of Brushless A.C Generator

Fig. 11 Sectional drawing for HF. 6 type generator (double sleeve bearing)

HFJ 6 (air to water cooling)

HFC 6 (air to air cooling)

Stator frame and stator windings assembly
Rotor and windings assembly
AC exciter assembly
Rectifier assembly (Fig.11-1)
Excitation equipment
Shaft
Bearing
Cooling fan
End shield AS/BS
Terminal box
Insulation for prevention of shaft current (Fig. 5)
Thermometer
Space heater
Cooler

Fig. 11-1 Rectifier assembly

Varistor module
Hub

14 << Operating Instructions Synchronous Generator

Connector rings
Rectifier module

02

Operating Instructions
Synchronous Generator

Excitation System (operation)

2.1 Mode of Operation (SPRESY 15)

Depending on the reference potential of terminal 16,

terminal 12 of the comparator point of the control

1) Description

amplifier can be given an additional D.C. pulse, e.g for

Brushless synchronous generators consist of the main

reactive power control in parallel operation.

machine and of exciter.

The main machine field winding is powered from the

For tuning to the signal level, a rheostat must be soldered

exciter rotor winding via a rotating, three-phase bridge-

onto the available soldering pins.

connected rectifier set.

The power supply for the gate control module(s) is

The exciter is THYRIPART-excited.

available from terminal 11.

Excitation equipment and thyristor voltage regulator are

Fig. 12 Voltage regulator; SPRESY 15

combined in the THYRIPART excitation system.

The excitation current required is supplied by the main
machine proper via the excitation equipment which is
adjusted to deliver a field current resulting in a generator
output voltage above the maximum reference value over
the entire load range when the voltage controller is
inactive.
The actual function of the voltage regulator is to provide a
bypass for a variable portion of the curent supplied by the
excitation equipment for controlling the generator voltage.
The thyristor regulator module consists of two
subassemblies: the regulator module and the firing module
with thyristor in buck circuit.
The three-phase generator voltage, having been reduced
to 24V by the measuring-circuit transformers, is applied

In the control circuit of the firing module, a time

to teminals 17,18 and 19.

adjustable firing impulse for the thyristor is formed from

A direct voltage of approx 30 V (teminal 20 to terminal 13

the control voltage of terminal 15 in comparison with a

or 14) is produced at the output from the rectifier bridge

saw tooth voltage.

at the rated voltage of the generator.

The overvoltage protector, which operates at voltages

This rectified voltage provides the actual value pulse and

over 600 V between terminals 1 and 5, then switches the

the supply to the control amplifier.

thyristor through.

The regulator module supplies output terminal 15 with a

The excitation current is normally bucked with a single

control voltage of approx.

pulse.

1 to 10 V, which is proportional to the control deviation.

If higher excitation is required two firing modules for twopulse "buck" operation will be provided.

Fig. 13 Block diagram of voltage regulator; SPRESY 15

Six-pulse recifier bridge

Referance/actual value comparator
Power supply
Control amplifier
Firing pulse control
Thyristor in buck circuit
Overvoltage protector
Auxilary power thyristor

Instruction Manual

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15

02

Excitation System (operation)

Fig. 14 Connection diagram of generator (for generator top mounted AVR)

Fig. 15 Connection diagram of generator (for panel mounted AVR)

16 << Operating Instructions Synchronous Generator

Operating Instructions
Synchronous Generator

2) Installation

3) Direction of rotation of the generator

The excitation equipment, thyristor voltage regulator,

The generators are generally suitable for clockwise and

main machine and exciter are supplied factory-wired.

anti-clock-wise operation.

If necessary, the mains leads and the reference-value

Generators which must run only in a definite direction of

selector, if should be connected to the terminals in the

rotation, have the rating plate marked with a

terminal box according to the connection diagram

corresponding direction arrow and with the addition

supplied with the machine.

"only".
If only one direction of rotation is permissible for electrical
reasons, the excitation system is connected in the works

2.2 Operation (SPRESY 15)

for the direction of rotation given in the order.

To change the direction of rotation it is necesssry to

1) Thyristor voltage regulator

change the connections according to the connection

When the generator is operating by itself, the thyristor

diagram and to check whether only one definite direction

voltage regulator controls the generator voltage to the

of rotation is permissible for mechanical reasons (e.g. fan

preset reference value.

with curved fan blades).

Frequency changes due to the droop characteristics of

the prime mover do not influence the accuracy of the
generator output voltage.

4) Regulator gain setpoint of voltage integral

action

Design and adjustment of the main machine, exciter,

The regulator module includes the three potentiometers

excitation equipment, thyristor voltage regulator and

Usoll, Vr and Tn.

reference-value selector permit gradual changes in the

The generator rated voltage was adjusted in the works

generator output voltage from 95% to 105% rated voltage

on potentiometer Usoll and the transient response

via potentiometer Usoll under steady-state conditions and

characteristic of the regulator on potentiometers Vr

at loads varying between no load to rated load and power

and Tn.

factors between 0.8 and unity, unless otherwise specified

The regulator gain is adjusted on the potentiometer Vr,

on the rating plate.

but the integral action time and the optimum transient

If the generators are operated at less than 95% or more

response characteristic are adjusted on the

than 105% rated voltage, their output must be reduced.

potentiometer Tn.

Unrestricted operation with no load (opened generator

breaker) and partial speeds is permissible.

Turning the knob of Vr in the direction of descending

numerals and that of Tn in the direction of ascending

During operation the excitation circuit must not be

numerals normally stabilizes the control circuit and

interrupted since this would give rise to voltage surges.

reduces the control rate.

If the generator must be de-excited this can be

accomplished by short-circuiting the field winding of the
exciter (terminals +F1 and -F2) (Fig.13).

The setpoint of the generator voltage can be shifted via

In this case, a dangerously high voltage may develop at

reference-value selector (R = 1.5

the generator terminals as a result of residual magnetism.

connected to auxillary terminals 20 and 21 (Fig. 13)

potentiometer Usoll and via a supplementary external

,P

1 W) to be

with the above potentiometer set to mid-position

(Subsequent extention of the setting range specified

2) Transformer adjustment

in the order-particularly for full output-is only possible

The tappings used on the transfomers are marked at test

following consultation).

report. It is strongly recommended that the original

adjustments be left unchanged.

The new adjustment of the potentiometer must be fixed

No responsibility can be assumed by the supplier for any

with the aid of the set screw.

damage or incorrect operation resulting from a change in

the original adjustments.
In the case of identical plants, the THYRIPART excitation
system or single parts may be interchanged if need arises;
those transformer tappings must always be used which
conform to the original transformer.

Instruction Manual

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17

02

Excitation System (operation)

5) Parallel operation, droop compensating

equipment

2.3 Maintenance (SPRESY 15)

DANGER

When provided with droop compensation, a brushless

synchronous generator is suitable for operating in parallel
with other generators or with a supply system.
The kW output is adjusted through the governor of the
prime mover.

Hazardous voltage
Will cause death, serious injury, electrocution or property
damage.
Disconnect all power before working on this equipment.

The speed characteristic of the prime mover should be

linear and rise by a min. of 3% and a max. of 5% between

No periodic maintenance inspections of the THYRIPART

rated load and no load.

excitation equipment are required.

Excessive dust deposits should, however, be removed

The droop compensating equipment ensures uniform

using dry, compressed air.

distribution of the reactive power and reduces the

In the case of faults it is advisable to the check voltage

generator output voltage in linear with the increase in

regulator, excitation equipment, and main machine with

reactive current.

exciter separately.

The droop compensating circuit is adjusted to provide a

generator voltage droop of 6% at zero p.f. and no voltage

For troubleshooting in the thyristor voltage regulator, all

droop at unity p.f. between no load and rated load as a

the leads connecting excitation equipment and thyristor

function of the generator current.

voltage regulator must be disconnected and, if fitted,

With this setting, a voltage droop of 3.6% is obtained at

the intermediate transformers of the droop-compensating

0.8 p.f.

equipment secondaries short-circuited.

In this case the generator voltage must rise above the

When operated by it self or in parallel with generators

maximum reference value as given under "Description".

having the same voltage characteristic, a voltage

accuracy of

1.8% is thus obtained if the rated voltage is

In this case the thyristor voltage regulator is defective.

adjusted by means of the setpoint potentiometer at 50%

Trouble shooting should be continued according to

generator load.

table 4-2 on page 46.

With the generator operating by itself, no droop

compensating equipment is required.
It can be deactivated by short-circuiting the secondary

2.4 Mode of Operation (6 GA 2491)

side of the intermediate transformers.

If the neutrals of alternators in a system are

1) Description

interconnected and/or connected directly to those of

Brushless synchronus generators consist of the main

transformers and loads, balancing currents of three times

machine and the exciter.

system frequency can occur.

The main machine field winding is powered from the

exciter rotor winding via a rotating, three-phase bridge-

Their magnitude must be measured in the alternator

connected rectifier set.

neutral conductors under all possible load conditions to

be met in service.

The exciter is THYRIPART-excited.

The excitation equipment and the thyristor voltage

To prevent the alternators from overheating, these

regulator are combined in the THYRIPART excitation

currents of three times system frequency must not

system.

exceed approximately 50% of the respective alternator

The field current required is supplied by the main machine

current.

via the excitation unit.

Excessive currents should be limited, e.g. by means of

neutral reactors or similar fitted on the plant side.

This is adjusted in such a manner that the generator

A specific enquiry is necessary for these items.

voltage which is above the maximum setpoint value

develops over the entire load range when the voltage
regulator is inactive (open plug connection X1).

18 << Operating Instructions Synchronous Generator

Operating Instructions
Synchronous Generator

The thyristor voltage regulator provides a bypass for

part of the current supplied by the excitation unit for
controlling the generator voltage.
The voltage regulator 6 GA 2492 is comprised of the
voltage regulator 6 GA 2491 and the power module
(rectifier, thyristor in "buck" circuit, and resistor in
"buck" circuit).
Fig. 16 Voltage regulator "6 GA 2491"
(for generator top mounting)

Fig. 17 Voltage regulator "6 GA 2491"

(for panel mounting)

Fig. 18 Block diagram of voltage regulator "6 GA 2491"

V29
U
T
V28

Excitation rectifiers
Reference value potentiomete
Potentiomenter, reset time
Thyristor in "buck" circuit

S
K
R47
R48

Droop potentiometer
Potentiometer, controller gain
Potentiometer, disturbance feedforward
Resistor in "buck" circuit

Power supply
Control amplifier
Pulse unit
Overvoltage protector
External reference value setter

Instruction Manual

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19

02

Excitation System (operation)

Fig. 19 Connection diagram of generator (for generator top mounted AVR): 35 Fr~40 Fr

Fig. 19-1 Connection diagram of generator (for generator top mounted AVR): 45 Fr~56 Fr

20 << Operating Instructions Synchronous Generator

Operating Instructions
Synchronous Generator

Fig. 20 Connection diagram of generator (for panel mounted AVR): 35 Fr~40 Fr

Fig. 20-1 Connection diagram of generator (for panel mounted AVR): 45 Fr~56 Fr

Instruction Manual

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21

02

Excitation System (operation)

2) Mode of operation of regulator

3) Installation

The generator voltage is fed to the regulator via plug

The excitation equipment, thyristor voltage regulator,

connector X1 in a single-phase, two-circuit arrangement.

main machine, and exciter are supplied factory-wired.

Transformer T1 steps down the generator voltage which

If necessary the main leads and the reference-value

is then rectified by the load-side rectifier bridge V1, V4.

selector must be connected to the terminals in the

This rectified voltage provides the actual pulse signal "Uist"

terminal box according to the connecting diagram

the setpoint voltage Usoll and the supply voltage

supplied with the machine.

for

the regulator.
If the system uses a reactive current compensator,
current trans-former T15 or interposing transformer T4

2.5 Operation (6 GA 2491)

of the excitation unit is connected to load resistor R1 via

plug-in contacts X2/5 and X2/9.

1) Thyristor voltage regulator

In this operating mode the actual voltage is composed

The voltage regulates the voltage so that it complies

of the secondary voltage of transformer T1 and the

with the setpoint selected.

voltage of load resistor R1.

Frequency changes due to the droop characteristics of

the prime mover do not affect the voltage accuracy.

The magnitude of the resulting reduction in generator

voltage can be set with potentiometer S.

The design and adjustment of the generator and the

If an external set point selector is used, this is connected

excitation equipment permit continuous changes of the

by contacts X2/1 (A1) and X2/3 (A3).

terminal voltage in the range of

In this case microswitch S1/3 of the regulator must be

the setpoint selector under steady-state conditions and

opened.

at loads varying from no load to rated load, and power

5% rated voltage via

factors from 0.8 to unity unless specified otherwise on

A DC voltage of 0 to 10 V can be fed in via plug-in

the rating plate.

contacts X2/6 and X2/2.

If several rated voltages and frequencies are indicated on

This voltage acts on the comparator point of the control

the rating plate, the above data apply to each of the rated

amplifier.

voltages stated.

The setpoint can thus, for instance, be preset by higher-

If the generators are operated at voltages exceeding un

level equipment.

5% the generator output must be reduced.

Unrestricted operation at no load is permitted if the speed

Control amplifier

(proportional again adjustable by

is reduced.

potentiometer K and reset time by potentiometer T)

outputs a DC voltage which is converted into a time-

During operation the excitation circuit must not be

adjustable firing pulse for thyristor V18 or V28 via the

interrupted since this would give rise to voltage surges.

loadside pulse unit

If the generator must be deexcited, this can be

accomplished by short-circuiting the field winding of the

The generator excitation circuit is fed from rectifier

exciter terminals +F1, -F2.

bridge V29.
Resistor R48 and thyristor V28 form a parallel bypass
circuit to the field winding through which part of the
current supplied by the excitation unit flows.
This method provides for generator voltage control.

NOTE
In this case a remnant voltage of approx.
5% to 10% rated voltage may develop at the generator
terminals.

In order to optimize the correcting action, a disturbance

variable is injected into the control amplifier via resistor
R47.

2) Transformer adjustment

Overvoltages above DC 600 V in the excitation circuit

cause the overvoltage protector

to operate and

continuously fire the thyristor.

Protection is thus provided for the stationary excitation
circuit of the generator.

The tappings used on the transformers are shown in the

test report.
It is strongly advised not to change the original
adjustments.
No responsibility can be assumed by the supplier for any
damage or incorrect operation resulting from a change in
the original adjustments.

22 << Operating Instructions Synchronous Generator

Operating Instructions
Synchronous Generator

In the case of identical plants, the THYRIPART excitation

Parallel connection on the exciter side or droop

system or the individual components can be interchanged

compensation equipment ensures uniform distribution

if the need arises.

of the reactive power and reduces the generator output

The transformer tapings, however must be used which

voltage in linear proportion to the increasing reactive

are shown in the circuit diagram of the generator and

current.

which correspond to those of the original transformer.

Regarding generators with current transformer for droop
compensaton, potentiometer S in the regulator is

3) Regulator gain, setpoint voltage integral action

adjusted so that there is no reduction in the generator

The control module comprises potentiometers U, K, T,

voltage at unity p.f. but a 6% reduction at zero p.f.

R47 and S.

The corresponding voltage reduction at 0.8 p.f. is 3.6%.

The rated generator voltage has been adjusted in the

In isolated operation and at any loading condition of the

works on potentiometer U, and the dynamic behaviour

generator, the droop compensation provided for the

of the regulator on potentiometers K, T and R47.

generator voltage can be checked with the following

The settings are shown in the test certificate.

relationship:

Potentiometer K is used to adjust the controller gain and

Ust = 6%

1-cos2

IB/IN (%)

potentiomter T is used to adjust the integral action time,

whereas potentiomter R47 is used to inject a disturbance

e. g. at 0.8 pf, IB/IN = 1,

variable into the comparator point of the control amplifier

in order to adjust dynamic behaviour.

Ust = 6%

1-0.82

1 = 3.6 (%)

Turning the knob of K and R47 in the direction of

descending numerals and that of T in the direction of
ascending numerals normally stabilizes the control circuit

If the generator is to operate by it self, droop

and reduces the control rate.

compensation equipment is not required.

The stability of the control circuit can also be improved by

It can be deactivated by short-circuiting the associated

increasing the bucking resistance, but the voltage setting

current transformer on the secondary side or setting

range of the regulator then is reduced at the lower end.

potentiometer S on the regulator to the left-hand stop.

If the neutral points of several generators are

The setpoint of the generator voltage can be shifted via

interconnected or connected direct with the neutral

potentiometer U or an additional external setpoint

points of transformers and loads, currents at 300%

selector (R = 4.7

frequency may occur.

, P greater than 1 W) can be connected

to terminals A1 and A3.

Potentiometer U should be set to the centre position, and

Their magnitude should be checked by measurements in

microswitch S 1/3 on the printed-circuit board should be

the neutral conductors of the generators under all load

opened.

conditions occurring.
To avoid overheating the generators, these currents must

4) Parallel operation droop compensation

equipment

not exceed a value equal to about 50% of the rated

When provided with droop compensation equipment,

Higher currents should be limited by installing neutral

brush less synchronous generators are suitable for

reactors or similar means.

generator current.

operating in parallel with each other or with a supply

system.
The KW output is adjusted by the governor of the prime
mover.
The speed characteristic of the prime mover should be
linear and rise by at least 3% and not more than 5%
between rated load and no load.

Instruction Manual

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23

02

Excitation System (operation)

Fig. 21 Droop characteristic curve

2.6 Maintenance (6 GA 2491)

DANGER
Hazardous voltage
Will cause death, serious injury, electrocution or property
damage.
Disconnect all power before working on this equipment.

No periodic maintenance inspections of the THYRIPART

excitation equipment are required.

Fig. 22 Position of potentiometers on the voltage regulator

24 << Operating Instructions Synchronous Generator

Excessive dust deposits should, however, be removed

using dry, compressed air.
For maintenance or the other parts of the generater refer
to trouble-shooting table 4-3, as shown on page 47.
When ordering spare parts, please state the type and
serial number of the generator as specified on the
rating plate.

03

Operating Instructions
Synchronous Generator

Maintenance

3.1 Installation & Inspection Check List

The purpose of this checklist is to ensure that all

installation and inspection work is fully carried out.

DANGER
Hazardous voltage
Will cause death, serious injury, electrocution or property
damage.
Disconnect all power before working on this equipment.

It is therefore essential for the list to be filled in carefully.

The number of relevant questions will depend on the
scope of the work to be carried out,
In the "Answer" column, "yes" or "no" or "n/a" (for "not
applicable") should therefore be checked off in each case.

NOTICE

In some lines, additional data or information must be

Before the initial starting for in-sevice, check the items on

table 3-1 for sure.
If not, may cause fatal damage in generator.

entered or irrelevant items deleted.

If any further explanations are necessary they should be
placed in the report or final spec of the generator.

Table 3-1. Installation & inspection check list

Condition of machines
before installation

Answer
Yes

N0

n/a

Installation

Three-phase A.C. machines

Standard checks

Packing of all machine

components undamaged?

Insulation resistance values

winding temperature
at

Paintwork undamaged?
Stator
General

3 phases/earthed frame:
phase/phase:
Measuring voltage:
(usually 500 V, DC)

Winding guards properly fixed

and locked?

Rotor

All parts of the enclosure

properly assembled?

Insulation resistance values

at
winding temperature

Stator foot bolts tightened

properly?

Rotor winding/earthed shaft:

Measuring voltage:
V
(always 500 V, DC)

Answer
Yes

N0

n/a

Installation

Stator dowel-pinned?
Earthing or protective conductor
connected?
HV machines must be connected
to the earth bus
by a conductor of equal
cross-section.

Electrical connections
Cables/bars properly connected?
Cable strain-relief connected?

LV machines are to be included

in the protection
arrangements by the connection
of the green-yellow
protective conductor or the
concentric conductor of the
cable to the protective
conductor connecting terminal.

Instruction Manual

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25

03

Maintenance

Table 3-2. Installation & inspection check list

Answer

Bearings
Yes
Journal bearings
(Lubricating oil used)
Oil grade
Viscosity
at
Condition of bearings and shaft
Have any shipping bearing shells
and/or shaft blocks been
removed?
Anti-rust coating removed?
shaft journals satisfactory?
Oil rings fitted in the bearings?
Circularity of oil rings
satistactory?
Oil-ring slots of bearings
shells deburred and rounded
off?
Joint locked?
Bearing sealing rings properly
fitted?
Bearing thermometers fitted?
All bearing bolts properly
tightened and locked?
Bearing filled with oil to
centre marks of oil-level sight
glasses?
Running of oil rings checked?

N0

n/a

Installation

Answer

Oil flow rates reference

Yes
Drive-end
journal bearing

/min

Non-drive-end
journal bearing

/min

N0

n/a

Installation

The specified oil flow rates are

indicated on the bearing instruction plate. With the specified
flow rates, about half the clear
cross-sections of the oil drain
pipes are filled with oil.
Rolling bearings
Grease lubrication
Type of grease

General
Check the flow of cooling water
(IP44):
Check the safety device in
service or. not?

Oil circulation system

Oil pipework cleaned and
pickled?
Pressure reducer fitted?

1) Inspection schedule
Daily

Monthly

Check bearing.

Check insulation resistance.

L.O. condition.

Caution: Before checking insulation resistance,

Oil ring.

disconnect and earthed the leads from A.V.R.

Noise.

Bolts and nuts.

Vibration.
Temperature.

Tighten all bolts and nuts.

Check electric circuit.

Check ventilation openings.

Earth fault by earth lamp.

Check air intake opening and its air filter, clean or

Check loading condition.

replace the filter if necessary.

Voltage, output kW, current.

26 << Operating Instructions Synchronous Generator

Operating Instructions
Synchronous Generator

Every 6
Monthly

Before the machines are aligned and commissioned,

Change lubrication oil and clean bearing.

the machines are delivered without oil in the bearings

At the same time, check fitting or seating of bearing.

(oil type is indicated on the name plate of the bearing).

the bearings should be filled with lubricating oil Since

Clean generator.
CAUTION
Flying dirt, dust or other particles.
May cause eye injury.
Wear safety glasses and dust mask when using
compressed air.

Inspect generator winding and air filters for dirt, dust, oil,
and salt vapor accumulation.
Blow off contamination by dry and oil free compressed air.
Wipe off accumulated vapor with a lint free colth and
adequate solvent.
Check electrical connection.
DANGER

2) Operating description
NOTICE
Before starting, check if the bearing is filled with oil or not
to the sufficient oil level.

Upon stopping, the shaft rests on the lower bearing; there

is metal-to-metal contact.
During the start-up phase, the shaft rubs against the antifriction metal of the bearing. Oil lubrication is used.
After having reached its transition speed, the shaft
creates its oil film.
At this point there is no further contact between the shaft

Hazardous voltage
Will cause death, serious injury, electrocution or property
damage.
Disconnect all power before working on this equipment.

Inspect for loose electrical connection.

and bearing.
CAUTION
Prolonged operation at extremely slow rotation speeds
(several rpm) without lubrication could seriously damage
the service life of the bearing.

Inspect cracked, frayed or oil soaked insulation.

Tighten or replace if neccessary.
CAUTION

3.2 Flange-Type Sleeve Bearing

(for ring lubrication system)

If the bearing temperature exceeds the normal operating

value of 15 K stop the machine immediately.
Inspect the bearing and determine the causes.

1) Mounting

3) Oil change

The flange-type sleeve bearings of electrical machines

Check the bearing temperature regularly.

are of the split type.

The governing factor is not the temperature rise itself,

They are ring-lubricated (Fig. 24) and are subject to the

but the temperature variations over a period of time.

following instructions supple menting and modifying the

If abrupt variations without apparent cause are noticed,

operating instructions of the machine:

shut down the machine and renew the oil.

Corresponding to the operating conditions the sleeve

The lubrication oil indicated on the data plate is used for

bearings of new machines have a favorable bearing

starting up the machines at an ambient temperature of

above +5 .

clearance which should not be changed.

Scraping (spot-grinding) is not allowed not to make worse
the antifrictional qualities.

At lower temperatures (to about -20 ) it is sufficient to

preheat the oil.

It is recommended that the contour of the transmission

If the ambient temperature is below -20

element remain within the hatched range (see Fig. 24)

oil according to the special conditions is used.

to remove the upper part of the bearing housing for

Do not mix oils of different grades.

another type of

maintenance without removing the transmission element.

Instruction Manual

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27

03

Maintenance

Recommended oil changing intervals are about 3000

4) Dismantling, assembling

and 6000 operating hours in the case of intermittent and

continuous duty.

CAUTION

When cleaning, first flush the bearings with kerosene

and then with oil.

When insulated shaft current is applied the accessories in

contact with the bearing housing must be electrically
insulated.

NOTE
If the lubricating oil contains unusual residues or is visibly
changed, an inspection.

When dismantling the machine the lower part of the

bearing housing need not be unscrewed from the end
shield. When opening the bearing housing, locate

Pour in the kerosene and oil through the top sight-glass

which side of the machine the adjusting shims

hole.

(upper and lower parts) are installed.

Leave the drain open until all the kerosene has been
removed and clean oil runs out.

These shims must be installed in the same place when

Now, plug the drain and fill the bearing with oil up to the

assembling the machine.

centre of the lateral inspection glass.

Exceptions are possible if the stator core was changed.
When the machine has run up to speed, check the oil ring

Drain the oil, take off the upper part of the bearing

through the top inspection glass to see that it rotates

housing and the upper bearing shell, lift the shaft very

correctly, and check the bearing temperature.

slightly and turn out the lower bearing shell and the
sealing rings in a peripheral direction.

Should the bearing temperature not drop to the normal

value after the oil change, it is recommended that the

The oil ring can be withdrawn by holding it at an inclined

surfaces of the bearing shells be inspected.

position to the shaft.

If the bearings are fitted with thermometers for checking

the bearing temperature, fill the thermometer well in the
upper bearing shell for thermofeeler with oil to improve
heat transfer and top up with oil every time the
lubricating oil is changed.

Fig. 23 Oil pockets and oil grooves

flattened to running face

28 << Operating Instructions Synchronous Generator

Operating Instructions
Synchronous Generator

If only slight damage has occurred to the bearing

The replacement bearing shells are delivered by the

surface, it may be re-conditioned by scraping, as long as

works with a finished inner diameter.

the cylindrical shape of the bore is maintained, so that a

Oil rings which have become bent through careless

good oil film can form.

handling will not turn evenly.

The lining must be renewed if more serious damage is

found.

Straighten or replace such rings.

The oil pockets and grooves of the new lining or scraped

Replace any damaged sealing rings.

shell should be cleaned and finished with

particular care (Fig. 23).

2
1
3
4

25
26

d1

45

Fig. 24 Ring-lubricated flange-type sleeve bearings (examples, delivered design may deviate in details)

14

d2

18
6
19
27
32

15

Limiting range for

transmission element
1
2
3
4

14

5
6
7
8
9

15

10

11

12

13
3
2

16
17

8
20

1. Screw plug
(thermometer mounting and oil filling point)
2. Inspection glass
3. Sealing ring for 2
4. Sealing ring for 1
5. Bearing housing, upper part, drive end
6. Cylindrical pin
7. Sealing ring, upper half, drive end
8. Guide pin to prevent twisting
9. Upper bearing shell, drive end
10. Oil ring, drive end
11. Lower bearing shell, drive end
12. Bearing ring, lower half, drive end
13. Sealing ring, lower half, drive end
14. Taper pin
15. Guide pin to fix bolted parts
16. Sealing ring for 17
17. Drain plug
18. Bearing housing, upper part, non-drive end
19. Sealing ring, upper half, non-drive end
20. Upper bearing shell, non-drive end
21. Oil ring, non-drive end
22. Lower bearing shell, non-drive end
23. Bearing housing, lower part, non-drive end
24. Sealing ring, lower half, non-drive end
25. Upper adjusting shim, drive end
26. Sealing cover, drive end
27. Lower adjusting shim, drive end
28. Upper adjusting shim, non-drive end
29. Sealing cover, non-drive end
30. Lower adjusting shim, non-drive end
31. Protective cap
32. Pressure compensation opening

21

22

23

24
3
2
16
17

28
29

31

30
32

d1 (mm)

80

100

120

150

180

215

d2 (mm)

140

160

170

190

210

245

a (mm)

10

15

18

22

Instruction Manual

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29

03

Maintenance

3.3 Flange-Type Sleeve Bearing

(forced lubrication system)

It is recommended to use a control system adjusted in

such a manner to have an oil temperature of 15 to 20
in the tank and to have a preheated oil flow through the

1) Mounting

cold bearings for 5 to10 minutes before starting up the

The flange bearings of these electrical machines are of

machine.

the split type.

Do not mix oils of different grades.

They are lubricated by an oil ring and are provided for by

additional forced lubrication (Fig. 26).

The necessary pressure of the oil entering the bearings

They are subject to the following instructions supple

and the oil flow rate are indicated on the data plate.

menting and modifying the operation instructions of the

Adjust these values when starting up the machine for the

machine:

first time and correct them when the bearing has attained

Corresponding to the operating conditions the sleeve

its normal running temperature.

bearings of new machines have a favorable bearing

The oil in the bearing housing must not ascend over the

clearance which should not be changed.

center of the lateral inspection glass.

Scraping (spot-grinding) is not allowed not to make worse

If the bearings are fitted with thermometers for checking

the antifrictional qualities.

the bearing temperature, fill the thermometer well in the

It is recommended that the contour of the transmission

upper bearing shell for the thermofeeler with oil to

element remains within the hatched range (see Fig. 26)

improve heat transfer and top up with oil every time the

to remove the upper part of the bearing housing for

lubricating oil is changed.

maintenance without removing the transmission element.

In the case of insulated bearings, make sure that the
Before the machines are aligned,the bearings should be

insulation is not bridged by the tubes.

filled with lubricating oil (oil type is indicated on the name

Interrupt the electrical conductivity of the tubes near the

plate of the bearing) since the machines are delivered

bearings, e.g. by installing oil-resistant fittings of plastic

without oil in the bearings.

material or hoses of rubber or plastic material.

Connect the bearings to the oil pump, oil tank and cooler
before commissioning the machines.

2) Operating description

No reducers must be fitted in the piping.

NOTE

Install a regulating orifice on the oil supply line to protect

the bearing from flooding.
If the oil pump fails, the lubrication maintained by the oil

Before starting, check if the bearing is filled with oil or not

to the sufficient oil level.

ring is effective for about 15 to 30 minutes, provided the

oil contained in the bearing does not drain away.

Upon stopping, the shaft rests on the lower bearing; there

is metal-to-metal contact.

To prevent this, connect the oil discharge tube on that

side where the oil ring moves downward into the oil.

During the start-up phase, the shaft rubs against the anti-

In addition to this, install a non-return valve in the oil

friction metal of the bearing.

supply line.

Oil lubrication is used.

As an alternative raise the level of the oil in the bearing

to 100 mm.

After having reached its transition speed, the shaft

Oil discharge tubes must terminate flush with the inside

creates its oil film.

surface of the bearing housing to prevent the oil rings

At this point there is no further contact between the shaft

from rubbing against the tubes.

and bearing.

Fill the oil tank with the lubricating oil indicated on the
data plate.
This oil is used for starting up the machine at an ambient
temperature of above +5

At lower temperatures preheat the oil.

30 << Operating Instructions Synchronous Generator

CAUTION
Prolonged operation at extremely slow rotation speeds
(several rpm) without lubrication could seriously damage
the service life of the bearing.

Operating Instructions
Synchronous Generator

CAUTION
If the bearing temperature exceeds the normal operating
value of 15 K stop the machine immediately.
Inspect the Bearing and determine the causes.

Switch on the oil pump before starting up the machine.

4) Dismantling, assembling
CAUTION
When insulated shaft current is applied the accessories in
contact with the bearing housing must be electrically
insulated.

The use of a pump driven from the shaft of the main

machine is permitted only in special cases, such as when

When dismantling the machine the lower part of the

the acceleration and coasting times are short.

bearing housing need not be unscrewed from the end

shield.
When opening the bearing housing, locate on which side

3) Oil change

of the machine the adjusting shims (upper and lower parts)

Check the bearing temperature regularly.

are installed.

The governing factor is not the temperature rise itself, but

the temperature variations over a period of time.

These shims must be installed in the same place when

If abrupt variations without apparent cause are noticed,

assembling the machine.

shut down the machine and renew the oil.

Exceptions are possible, if the stator core was changed.

Drain the oil, take off the upper part of the bearing housing

Recommended oil changing intervals are about 20,000

and the upper bearing shell, lift the shaft very slightly and

operating hours.

turn out the lower bearing shell and the sealing rings in a
peripheral direction.

After the machine has come to a stand-still and the old oil

The oil ring can be withdrawn by holding it at an inclined

is drained out of the bearings and oil tank operate the oil

position to the shaft.

pump with kerosene for a short time and then with oil to
clean the bearings.

If only slight damage has occurred to the bearing surface,

it may be reconditioned by scraping as long as the

For the oil pump, the oil tank, the cooler and the pipe

cylindrical shape of the bore is maintained, so that a good

lines: Pour in the kerosene and then the oil through the

oil film can form.

filling opening of the oil tank.

The lining must be renewed if more serious damage

Leave the drains open from time to time until all the

is found.

kerosene has been removed and clean oil runs out of the

The oil pockets and grooves of the new lining or scraped

bearings and oil tank.

shell should be cleaned and finished with particular care

Then plug the drains and fill the tank with oil.

(Fig. 25).

Should the bearing temperature not drop to the normal

value after the oil change, it is recommended that the

The replacement bearing shells are delivered by the works

surfaces of the bearing shells be inspected.

with a finished inner diameter.

Oil rings which have become bent through careless
handling will not turn evenly.
Straighten or replace such rings.
Replace any damaged sealing rings.

Fig. 25 Oil pockets and oil grooves

flattened to running face

Instruction Manual

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31

03

Maintenance

Fig. 26 Flange-type sleeve bearing for forced-oil lubrication (examples, delivered design may deviate in details)

1
2
3
4

14

5
6
7
8
9

15

10

11

12

13
3
2

1. Screw plug
(thermometer mounting and oil filling point)
2. Inspection glass
3. Sealing ring for 2
4. Sealing ring for 1
5. Bearing housing, upper part, drive end
6. Cylindrical pin
7. Sealing ring, upper half, drive end
8. Guide pin to prevent twisting
9. Upper bearing shell, drive end
10. Oil ring, drive end
11. Lower bearing shell, drive end
12. Bearing housing, lower part, drive end
13. Sealing ring, lower half, drive end
14. Taper pin
15. Guide pin to fix bolted parts
16. Sealing ring for 17
17. Drain plug
18. Bearing housing, upper part, non-drive end
19. Sealing ring, upper half, non-drive end
20. Upper bearing shell, non-drive end
21. Oil ring, non-drive end
22. Lower bearing shell, non-drive end
23. Bearing housing, lower part, non-drive end
24. Sealing ring, lower half, non-drive end
25. Upper adjusting shim, drive end
26. Sealing cover, drive end
27. Lower adjusting shim, drive end
28. Upper adjusting shim, non-drive end
29. Sealing cover, non-drive end
30. Lower adjusting shim, non-drive end
31. Protactive cap
32. Pressure compensation opening
33. Oil supply tube with orifice
34. Oil discharge tube with sight glass

2
1
3
4

14

18
6
19
15
8
20

21

22

23

24
3
2
16
17

28
29

31

25
26
100mm

d2

d1

45

16
17

30
32

33
27
32
Limiting range for
transmission element

32 << Operating Instructions Synchronous Generator

34

d1 (mm)

80

100

120

150

180

215

d2 (mm)

140

160

170

190

210

245

a (mm)

10

15

18

22

Operating Instructions
Synchronous Generator

3.4 Rolling-Contact Bearing (series 02 and 03)

Initial lubrication of the bearings is normally carried out in

the works with an Alvania #2 grease satisfying the

1) Mounting

conditions of the running test at a test temperature of

Electrical machines fitted with rolling-contact bearings

120

mentioned above are subject to the following

If a different type of grease is required, this is indicated on

instructions supplementing and modifying the operating

the data plate, provided that the particular operating

instructions of the machine:

conditions were given in the order.

to DIN 51 806.

CAUTION

The locating bearings are deep-groove ball bearings for

horizontally mounted machines.
These bearings may also be in pairs with cylindrical roller
bearings in the case of bearings is not guide radially and

Do not mix grease of different soapbases.

When changing the type of grease, clean the bearing
beforehand using a brush with solvent.

is prevented from rotating by compression springs.

NOTE

The locating bearings for vertically mounted machines are

angular-contact ball bearings of type range 72 or 73

The most widely-used solvent is gasoline: white spirit is

acceptable.

(angular-contact ball bearings with increased axial fixation

see suplementary operating instructions).
The floating bearings are deep-groove ball bearings or
cylindrical roller bearings.
In the case of deep-groove ball bearings as floating
bearings, the axial play is compensated by means of
compression springs.

2) Regreasing

DANGER
The prohibited solvents are:
Chlorinated solvent (trichlorethylene, trichloroethane)
which becomes acid.
Fuel-oil (evaporates too slowly).
Gasoline containing lead.
Benzine (toxic)

For regreasing, clean the lubricating nipple and press in

the grease quantity indicated on a data plate, using a
NOTE

A common mistake is over-lubrication of bearings. When

grease is added without removing the drain plug, the
excess grease must go somewhere and usually it is forced
into and through the inner bearing cap and is then thrown
into the windings. Proper lubrication is desired, but some
under-lubrication is less dangerous than over-lubrication.

grease gun.
Keep the new grease meticulously clean.

Fig. 27 Examples for bearing combinations

Deep-groove ball bearing

Cylindrical roller bearing
Angular contact ball bearing

Instruction Manual

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33

03

Maintenance

The shaft should rotate during regreasing, hence the

4) Dismantling, assembling

machines need not be stopped.

For working on the locating bearing in the vertical

After regreasing, the bearing temperature will rise by a

position of the machine, support or discharge the rotor.

few degrees and will drop to the normal value when the
grease has reached its normal service viscosity and the

It is recommended that new rolling bearings be installed

excess grease has been forced out of the bearing.

as follows: Heat the ball bearings or the inner ring of the

roller bearings in oil or air to a temperature of approx 80

It is recommended that the lubricating instructions be

and slip them onto the shaft.

strictly followed.

Heavy blows may damage the bearings and must be

Special cases may require lubrication according to special

avoided.

instructions, e.g. where there is an extreme coolant

temperature oraggressive vapours.

When installing single angular-contact ball bearings, make

sure that the broad shoulder of the inner ring (and the

The old grease from several regreasing operations gathers

narrow shoulder of the outer ring) in operating

in the space inside the outer bearings caps.

position points upwards, i.e. in a direction opposite to

Remove the old grease when overhauling the machines.

that of the axial thrust.

The model of bearing is favorably chosen for direction and

When assembling the machines, avoid damage to the

size of load (type of construction, forces acting on the

sealing rings.

shaft) and therefore it should not be hung.

Rubber sealing rings (V-rings) should be carefully fitted

The permissible values of axial and radial forces may be

over the shaft as shown the illustration.

taken from the list of machine or may be inquired about.

New felt sealing rings should be so dimensioned that the
The machines should operate in only one type of

shaft can run easily while proper sealing is still effected.

construction as shown on the rating plate, because

Before fitting new rings, soak them thoroughly in highly

another type of construction requires perhaps further

viscous oil (normal lubricating oil N68 to DIN 51 501)

measures in addition to a modification of the model of

having a temperature of approx 80

bearing.
In this case an inquiry is always necessary.

5) Locating faults
3) Lubrication

The trouble shooting table 4-6 helps to trace and remove

the causes of faults as shown on page 49.

Regrease the bearings if the machines have been

Sometimes it is difficult to assess damage to the bearings.

unused/stored for longer than 2 years.

In this case, renew the bearings.

34 << Operating Instructions Synchronous Generator

Operating Instructions
Synchronous Generator

Fig. 28 Floating bearings (examples, delivered design may deviate in details)

Cylindrical roller bearing

Deep-groove ball bearing

with compensation of
axial play

Deep-groove ball bearing

with compensation of
axial play, with bearing
housing brush and
intermediate ring

V-ring 1)
Outer bearing cap 1)
Circlip 1)
Grease slinger 1)
Bearing housing 1)
Lubricating nipple
Cylindrical roller bearing 1)
Inner bearing cap with felt sealing rings 1)

Deep groove ball bearing (floating-bearing)

Compression spring 1)
Bearing housing ring
Bearing housing brush
Cylindrical pin

1)

floating bearing side

Instruction Manual

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35

03

Maintenance

Fig. 29 Locating bearings (examples, delivered design may deviate in details)

Single bearing, shaft

does not pass through
the outer bearing cap

Single bearing, shaft

passes through the
outer bearing cap

Duplex bearing, shaft

does not pass through
the outer bearing cap

Angular-contact ball
bearing placed below

Angular-contact ball
bearing placed below
Duplex bearing, shaft
passes through the
outer bearing cap

Lubricating nipple
Inner bearing cap with felt sealing rings 2)
Angular-contact ball bearing
Bearing slinger 2)
Grease slinger 2)
Circlip 2)
Outer bearing cap 2)
V-ring 2)
Deep-groove ball bearing (locating bearing)
or angular-contact ball bearing
Compression spring 2)
Cylindrical roller bearing 2)
Cylindrical roller bearing 2)
Oil seal for shaft 1) 2) 3)
floating bearing side
locating bearing side
3)
special operating conditions only

Fig. 30 Fitting instructions for V-ring and oil seal for shaft

1)

2)

36 << Operating Instructions Synchronous Generator

Single bearing, shaft does not pass through the outer bearing cap

Operating Instructions
Synchronous Generator

3.5 Coupling A-type (single-bearing generators

with flanged shaft and one-part fan wheel)

Insert shims underneath the mounting feet until the

centering faces of the generator flange and engine
(flywheel) or gear flange are in line with the flanges being

1) Transport, storage

parallel to each other.

The following instructions supplementing and modifying

the basic.

Experience shows that less shims are required at the non-

Operating Instructions apply to single-bearing

drive end than at the drive end, since the engine coupling

generators of type of construction B2 or B16 which are

flange is inclined by the weight of the flywheel.

coupled with diesel engines or turbines:

Bolt the coupling flanges together while re-pressing the

generator axially, lightly tighten the foot bolts, and undo

For transport and assembly, the generator rotor is

the retaining-ring halves.

centered radially and fixed axially by means of bolted

retaining-ring halves fitted between the end shield AS
(unsplit) and the shaft supporting ring (Fig. 31).

3) Checking the air gap (Fig. 33)

The ring halves should therefore not be detached before

Check the air gap between the shaft supporting ring and

the generator is assembled with the diesel engine or

the end shield AS.

turbine.

The gap should be uniform all around.

If the maximum difference between the measured

Fig. 31 Rotor locking device (example, delivered

design may deviate in details)

values "a max-a min" exceeds 0.3 mm, correct the gap
by inserting or removing shims underneath the
mounting feet.
Experience indicates that the number of shims to be
inserted or removed at the non-drive end is only 50%
of the number at the drive end.
Tighten the holding-down bolts and check the web
clearance of the diesel engine.
It may be necessary to correct the air gap and the web
clearance several times.

End shield AS
Retaining ring half
Shaft supporting ring

Flanged shaft
Fixing screw for 1
Fixing screw for 3

Fig. 32 Aligning the coupling flanges

2) Aligning the coupling flanges (Fig. 32)

Careful alignment of the coupled machines prevents
additional bearing and shaft stresses, in acklition to
uneven and noisy running.
It is particularly important to achieve a uniform air gap.
The machine may be installed on a concrete foundation or
a baseframe.

Fig. 33 Checking the air gap and the position of the rotor

Check to see that the machine seating surfaces have

been made in accordance with the drawings.
The generator should be aligned with the diesel engine or
the turbine with gearing (the prime mover should have
already been installed and aligned in accordance with the
manufacturer's instructions).
The generators are aligned and coupled as follows: Place
the generator onto the concrete foundation or baseframe.

Instruction Manual

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37

03

Maintenance

Fig. 34 Fixing of the retaining-ring halves after

assembling with prime mover

4) Position of rotor in longitudinal direction (Fig. 33)

Fig. 35 Rotor locking device (example, delivered

design may deviate in details)

Indicator for magnetic center

Piece for air gap adjustment
Support plate

Washer
End shield AS

Originally, the generator rotor had been located axially

in the correct position by the bolted-on retaining-ring
halves.
Since single-bearing generators have a floating (rolling or
sleeve) bearing at the non-drive end, the axial position of
the rotor may have been changed during alignment.

2) Aligning the coupling flanges (Fig. 36)

Careful alignment of the coupled machines prevents
additional bearing and shaft stresses, also uneven and
noisy running.
It is particularly important to achieve a uniform air gap.

A check should therefore be made to ensure that the axial

clearance of (6 0.8)mm between the flange faces

The machine may be installed on a concrete foundation

or a baseframe.

of the end shield AS and the shaft supporting ring has

been maintained.
Otherwise the stator frame should be shifted axially.

Check to see that the machine seating surfaces have

been made in accordance with the drawings.
The generator should be aligned to the diesel engine i.e.
the prime mover had already been installed and aligned

5) Fixing the retaining-ring halves

Thereupon, screw the retaining-ring halves to the end
shield AS as shown in Fig. 34.
The ring joint should be vertical.
Close off the threaded holes in the retaining-ring halves
by means of the screws supplied, and lock the screws
with spring washers.

in accordance with the manufacturer's instrutions.

The generators are aligned and coupled as follows: Place
the generator onto the concrete foundation or baseframe.
Insert shims underneath the mounting feet until the
centering faces of genertor flange and engine (flywheel)
are in line with the flanges being parallel to each other.
Experience shows that less shims are required at the nondrive end than at the drive end, since the engine coupling
flange is inclined by the weight of the flywheel.

3.6 Coupling B-type (single-bearing generators

with flanged shaft)

Bolt the coupling flanges together while re-pressing the

generator axially, lightly tighten the foot bolts and remove
the pieces for air gap adjustment.

1) Transport, storage (Fig. 35)

The following instructions supplementing and modifying
the basic.

3) Checking the air gap (Fig. 37)

Operating instructions apply to single-bearing generators

Check the air gap between the shaft and the end shield AS.

of type of construction B2 or B16 which are coupled with

The gap should be uniform all around.

diesel engine.

For transport and assembly, the generator rotor is

centered radially and fixed axially by means of bolted.

supporting plate fitted between the sleeve bearing and

the shaft.

If the maximum difference between the measured values

The support plate must be detached during the coupling

"a max-a min" exceeds 0.3 mm, correct the gap by

work on the common bed with engine and generator.

inserting or removing shims underneath the mounting feet.

(Fig. 35-item 3)

38 << Operating Instructions Synchronous Generator

Operating Instructions
Synchronous Generator

Experience indicates that the number of shims to be

3) With axial end play at bearing

inserted or removed at the non-drive end is only 50% of

In this case, the axial position of the rotor assembly was

the number at the drive end. Tighten the foot bolts and

adjusted during the initial test at the factory.

the web clearance of the diesel engine.

It may be necessary to correct the air gap and the web

The generators are delivered with a magnetic center

clearance several times.

gauge an the drive bearing side with a groove on the

shaft and must be kept in the rotor position during the

Fig. 36 Aligning the coupling fanges

alignment with the prime mover.

3.8 Air Filters

1) Air filter cleaning period
The cleaning period depends on the site conditions and
can change.
The cleaning of the filter is requested if the record of the
stator winding temperature (using the stator winding
Fig. 37 Checking the air gap and the position of the rotor

sensors) indicates an abnormal increase in temperature.

2) Air filter cleaning procedure

The filter element (flat or cylindrical) is immersed in a
tank of cold or warm water (temperautre less than 50 ).
Use water with detergent added.
Shake the filter gently to ensure that the water flows
through the filter in both directions.
Fig. 38 Installation for air filter

Fixing of the piece for air gap adjustment after assembling

with the prime mover.

3.7 Coupling (double bearing generator)

1) Fitting the coupling element
The coupling element must be balanced separately
before fitting the machine shaft.
A residual unbalance of coupling element should be
less than class G 2.5 grade to ISO standard.

2) Without axial end play at bearing

The alignment must take the tolerance of the coupling
element into account.
The axial, radial and angle tolerance are to be acceptable
by coupling element property.
Filter unit, complete
Outer filter holder
Filter mat

Inner filter holder with frame

Cover

Instruction Manual

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39

03

Maintenance

When the filter is clean, rinse it with clear water.

The supply leads should be matched to the rated current

Drain the filter properly (there must be no more formation

in line with VDE0100 and their cross section must not be

of droplets).

excessive.
The main circuit is normally connected at both sides of

Refit the filter on the machine.

the circuit bars with conductor cross sections of max.

300

CAUTION
Do not use water with a temperature higher than 50 ,
do not use solvents.

and may be made by cable lugs or when

connecting parts used in hazardous locations which are

present without any lugs.
The ends of the conductors should be stripped in such a

Do not clean the filter using compressed air.

way that the remaining insulation almost reaches up to

This procedure would reduce filter efficiency.

the lug or terminal (

5 mm).

In the case of cable lugs with long sleeves, it may be

necessary to insulate the latter to maintain the proper
clearances in air.

3.9 Terminal Box

If using cable lugs, see that the dimension of the cable

lugs and its fastening elements (normally M12) agree with
DANGER

High voltage
Power source must be disconnected before working on
equipment.
Failure to disconnect power source could result in injury
or death.
Terminal box only to be opened by skilled personnel.

the holes in the copper bus bar.

Use hexagon-head screws with a min. breaking point of
500 N/ , hexagon nuts and spring elements which are
protected against corrosion according to DIN 43673.
The connection of accessories is achieved by terminal
strips.

1) Description
Use the attached terminal box drawing in the final
specification.
The main terminal box of the machine is located on the
top of the machine.
The neutral and phase wires are connected to the copper
bus bar-one copper bus bar per phase and one copper
bus bar per neutral line (option).
See terminal box diagram in the final specification.
The openings provide access to the terminals.
The gland plates are made of non-magnetic materials in
order to avoid circulating currents if needed.
Compare the supply voltage with the data on the rating
plate. Connect the supply leads and the links in
accordance with the circuit diagram on the inside of the
terminals box.
Pay attention to the right direction of rotation (phase
sequence in the case of three phase and polarity in the
case of direct current).

40 << Operating Instructions Synchronous Generator

Use a 5 mm maximum screwdriver to work on the

blocking screws.
See the terminal connection diagram in the final
specification.
The supply leads

particularly the protective conductor

should be laid loosely in the terminal box with an extra

length for protecting the cable insulation against splitting
and to prevent the terminals and circuit bars from the
tension load of the leads.
They should be introduced into the terminal box through
cable entry fittings and sealed.
Protected fittings with strain relief cleats should be used
for loose leads to prevent them from becoming twisted.
Close off any unused cable-entry openings.

Operating Instructions
Synchronous Generator

3.10 Disassembly of A.C. Generator (Fig. 39 and 40)

Fig. 39 For single bearing type A.C. generator
{

Coupling

Anti-coupling

side

side

1. Take away bolts ,

2. Take away support ring (upper part)
3. Take away bolts ,
4. Take away bearing upper part
5. Take away bearing shell
and oil ring
6. Take away bolts
and support ring under
part
7. Take away bolts
and bearing under part
8. Take away endshield ,

9. Insert protective sheet

10. Take away bolts
11. Draw out fan

12. Hang the shaft end with rope both side.

13. Shift the rotor toward anti-coupling side.
(shaft journal should be protected from
any damages by wrapping in cloth)

14. Shift the rotor assembly to anti-coupling

side as left description.
15. Hang the rotor assembly at its center
position by the rope.
16. Take away the rope of coupling side.

17. Take away the rotor out of the stator.

Instruction Manual

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41

03

Maintenance

Fig. 40 For double bearing type A.C. generator

Coupling

Anti-coupling

side

side

1. Take away bolts

2. Take away bolts
3. Take away bearing upper part
4. Take away bearing shell
and oil ring
5. Take away bolts
and bearing under
part
6. Take away endshield

7. Insert protective sheet

8. Take away bolts
9. Draw out fan

10. Hang the shaft end with rope both side.

(shaft journal should be protected from
any damages by wrapping in cloth )
11. Shift the rotor toward anti-coupling side.

12. Shift the rotor assembly to anti-coupling

side as left description.
13. Hang the rotor assembly at its center
position by the rope.
14. Take away the rope of coupling side.

15. Take away the rotor out of the stator.

42 << Operating Instructions Synchronous Generator

Operating Instructions
Synchronous Generator

3.11 Cooler

3) Stop the machine

Leak detection for a double-tube exchanger:

1) General points

If a leak is detected, cut off the power supply of the water

The purpose of the cooler is to remove machine heat

in/outlet lines and change to emergency operations

losses (mechanical, ohmic etc).

according to Fig. 44 and 46 immediately.

The exchanger is located on the top of the machine.

The problem must be ascertained and repaired.

Remove the two water boxes, apply a slight positive

Normal operation:

pressure in the leakage chamber and thus between the

The air is pulsed by a fan fixed to the synchronous

two tubes (only concerns double-tue coolers).

machine shaft.

If a tube is damaged, plug it at both ends.

Use a tapered plug.

Description of air-water double tube exchanger

Preferably the plug should be made of salt-water

The double-tube technique keeps the cooling circuit from

resistant aluminium bronze or a synthetic material.

being affected by possible water leakage.

The double tube provides a high safety level.
In case of leakage, the water goes from the inside of the

4) Leak detection (float system)

internal tube to the coaxial space between the two tubes.

A magnet float activates a switch located in the float

The water is drained axially to a leakage chamber where

guiding rod.

it may activate a sensor.

Fig. 41 Leakage detector

An exchanger comprises a fin-tube block containing:

a steel frame.
a fin-tube block expanded mechanically to the tubes.
The tube bundle is roll-expanded in the end plates.
The water distribution in the tubes is provided by two
removable water boxes.
A water box is equipped with collars for fitting the inlet
and outlet lines.
Neoprene seals ensure watertightness between the water
boxes and the end plates.

2) Cleaning
The frequency of cleaning operations depends essentially
on the purity of the water used.
We recommend a minimum of one inspection per year.

5) Cooler removal

The life of zinc block for anti-corrosion is about a year.

The cooler unit is slid into its housing.

Therefore replace it with a new one every year.

It is possible to remove the cooler from the housing

Cut off the water supply by isolating the inlet and outlet

without removing the water boxes as shown in Fig. 42.

lines, and drain the water.

The cooler is fastened to the housing via a series of

screws on the housing.

Disconnect the leak sensor (option with double-tube

Remove the supply and return pipes.

cooler), and make sure that there are no leaks.

Provide two eye-bolts to hold the cooler when it comes

Remove the water boxes on each side of the machine.

out of its housing.

Rinse and brush each water box.

Remove the cooler using slings that can be attached to

the connecting flanges.

NOTE
Do not use a hard wire brush as this will remove the
protective tar-epoxy layer which has formed on the
surfaces of the water boxes.
Clean each tube with a metal scraper.
Rinse in soft water.
Keep the leakage chamber dry (double-tube water-cooler
only)

6) Cooler re-assembly
Carry out the operations of the "Cooler Removal" Fig. 42
in the reverse order. Be careful to push the cooler
completely into its housing before tightening the
fastening screws of the cooler to the casing.

Instruction Manual

>>

43

03

Maintenance

3.12 Cooling-Water Failure Emergency Operation

The following supplements the machine description and

the module for the closed-circuit cooling.

1) HFJ 5. Type

Should the cooling water supply for the electrical machine

(1) Changing over to oepn-circuit cooling

fail, the machine can be changed over to an open cooling

The electrical machine has a facility for emergency

circuit (Fig. 44), as follows:

operation if the cooling water supply fails.

The electrical version of the alternator remains

unchanged.

Fig. 42 Cooler removal

Open the air vents at the BS-end for the air inlet and
at the AS-end for the air outlet (Figs. 43 and 44 - No.
3 & 5),
Remove enclosure or cover 2 (Fig. 43)
Insert air cut-off plate 6 (Fig. 44) into the slot in the
raised section on the housing on the hot air side of
the cooler and secure.
(2) Changing over to closed-circuit cooling
Operation should be changed back from emergency to
normal operation with air-to-water closed-circuit cooling
Cover
Gasket for 1
Cooler housing

Gasket for 5
Air to water cooling element

Fig. 43 Normal operation with air-to-water

closed-circuit cooling

Air vent with cover AS-end, closed.

Enclosure or cover.
Air vent with cover BS-end, closed.
Air-to-water cooler.

44 << Operating Instructions Synchronous Generator

as soon as possible by reversing the sequence described

as below.

Fig. 44 Emergency operation with open cooling circuit

following failure of the cooling water supply

Air vent with cover AS-end, open.

Air cut-off plate before insertion.
Air cut-off plate, inserted and screwed tight.
Air vent with cover BS-end, open.

Operating Instructions
Synchronous Generator

2) HFJ 6, Type

Detach the cover (part 2) from the side opposite the

(1) Changing over to open-circuit cooling

cooling water connections, insert the air-stop plate

On failure of the cooling-water flow the following

(part 3) which was supplied loose, and secure with the

operations are required to convert the generator for

screws provided.

emergency operation with internal cooling.

The electrical version of the alternator remains

(2) Changing over to closed-circuit cooling

unchanged.

Air-to-water colling element

Detach louvered covers (parts 4) together with the

Cover for No. 1

closure plates (parts 5) at the drive and nondrive ends,

Air-stop plate (emergency operation)

remove closure plates and attach louvered covers in

Louvered cover (emergency operation)

their original positions.

Closure plate

Fig. 45 Normal operation with air-to-water closed-circuit cooling

Cover for No 1.
Louvered cover (emergency operation).
Closure plate.

Fig. 46 Emergency operation with open cooling circuit following failure of the cooling water supply

Air-to-water cooling element.

Air-stop plate (emergency operation).
Louvered cover (emergency operation).

Instruction Manual

>>

45

04

Trouble Shooting

4.1 Excitation Part for SPRESY 15

If the voltage does not be induced, either the excitation

equipment or the main machine or the exciter can be

In the case of faults it is advisable to check the voltage

defective. Troubleshoot according to Table 4-4.

controller, excitation equipment, and main machine with

Information concerning voltage values for the thyristor

an exciter separately.

regulator module is given overleaf and assists in the

For troubleshooting in the thyristor voltage controller all

location of faults.

the leads connecting excitation equipment and thyristor

Table 4-1. Excitation part

voltage controller must be disconnected and if present,

the intermediate transformers of the droop-compensating

Terminal 20-14

equipment secondaries short-circuited.

Terminal 15-14

about 1 V

about 10 V

about 1 V

about 10 V

Fault
location
(Fig.13)

Regulator
module

Firing
module

Firing
module

Regulator
module

In this case the generator voltage must rise above the

maximum reference value as given under "Description".

< 30 V

> 30 V

In this case the thyristor voltage controller is defective.

Troubleshooting should be continued according to

If the remnant should not be adequate for exciting the

Table 4-2.

generator, a D.C. voltage (6 to 24 V) must be connected

to terminals F1 and F2 (+ to F1, - to F2) for a short time.
DANGER

Please note that the terminals F1 and F2 start carrying a

voltage as soon as self-excitation sets in.

Hazardous voltage
Will cause death, serious injury, electrocution or property
damage.
Disconnect all power before working on this equipment.

When ordering spare parts please state the type and

serial number of the generator, as they are shown on the
rating plate.

No wiring links
Wiring links in wrong position
Controller
module

Connected improperly
Wrong setting of potentiometer Usoll
Wrong setting of potentiometer VR or TN
Internal defect
Discontinuity

Power thyristor

Blocking failure
Gate electrode failure
Discontinuity

Measuring-circuit
transformer

Inter-turn fault
Connected improperly

Reference-value
selector

Discontinuity
Short-circuit in leads
Discontinuity

Series resistor

Resistance too high

Resistance too low
Discontinuity

Intermediate
transformer

Short-circuit
Connected improperly
Discontinuity

Tandem
potentiometer

Resistance too high

Resistance too low
Connected improperly

46 << Operating Instructions Synchronous Generator

Power thyristor
defective

Controller module
defective

Reactive current
too low

Reactive current
too high

Reactive power
hunting

Parallel (system)
operation

Active power
hunting

Voltage and current

hunting

Genetator voltage
too low

Cause

Genetator voltage
too high

Electric fault symptoms

Genetator excitation
fails

Table 4-2. Fault diagnosis chart for thyristor voltage regulators

Operating Instructions
Synchronous Generator

4.2 Excitation Part for 6 GA 2491

DANGER
Hazardous voltage
Will cause death, serious injury, electrocution or property
damage.
Disconnect all power before working on this equipment.

Drive speed

Load sharing in
parallel operation
not proportional

Fault

Voltage and
current swing

Genetator voltage >1.1

UN, not adjustable via
set point selector
External set point
selector
without function

Possible cause

Genetator voltage
<0.1 UN

Fault

Genetator voltage <UN,

not adjustable via set
point selector

Table 4-3. Fault diagnosis chart for thyristor voltage regulators

Remedies

Too high
Too low

Check speed control of prime mover.

Speed oscillation
Rotating rectifier defective

Unsolder diode connections, check diodes in

forward and reverse direction, replace diodes.

Interruption of exciter circuit

Check plug connection X 2 (only open X 2 with the

generator at standstill), check terminal strip X 6,
and X 7, check plug connections on rectifier
transformer and reactor.

Exciter remnant no longer

sufficient

Short-time connection of F1(+) and F2(-) with

Dc source(6 to 24V) via decoupling diode.

Interturn short-circuit or
interruption of the main
machine/exciter winding
(rotor or stator/winding grade
of excitation unit)

Check-winding resistances at cold state.

Voltage regulator
defective

Control section

Replace voltage regulator.

Power section

Replace modules.

Interruption of actual-value
input on controller

Check plug connection X1 and the leads bet-ween

terminals V, W and plug connection X1.

closed
Switch
S1-3 on
controller
open
Fault in PCB
setpoint
selector Short-circuit in the
circuit
leads

Open switch S1-3 on the voltage regulator.

Interruption in
connection

During operation without the external reference

value setter, S1-3 on the voltage regulator must be
closed (solder).
Eliminate short-circuit in the leads connected to the
extemal reference value setter.
Establish the connection to the external reference value
setter leads.

Potentiometers on voltage
regulator maladjusted

Adjust potentiometers K and T on the voltage

regulator in accordance with the test report or
adapt the voltage regulator to the plant by adjusting
potentiometers K and T.

droop potentiometers
maladjusted

Adjust potentiometer S for generators with droop

compensation transformer as per test report.

Interruption or short-circuit in
leads between droop
compensation transformer and
voltage regulator

Eliminate short-circuit or interruption.

Check current transfomer and plug connection
X2 in the case of interruption
(current transformer without burden).

Resistor in "buck" circuit

maladjusted

R48 to be increased.

Instruction Manual

>>

47

04

Trouble Shooting

4.3 Main Machines and Exciters (HF. 5 and 6)

DANGER
Hazardous voltage
Will cause death, serious injury, electrocution or property
damage.
Disconnect all power before working on this equipment.

Table 4-4. Fault diagnosis chart for excitation equipments, main machines and exciters

Incorrect
service
conditions or
duty under
conditions
deviating from
order
specifications

Overload
Speed deviating from set point
Excessive deviation from rated power factor
Incorrect operation, e.g.paralleling with
2nd generator in phase opposition
Stator
Main machine
Rotor

Inter-turn fault
Stator
Exciter
Rotor
Stator
Main machine
Rotor

Winding
discontinuity

Stator
Exciter
Rotor

Defective rotating rectifier

No remanence
Inter-turn fault
Transformer
Winding discontinuity

Faults on
excitation
equipment

Single-phase
current transformer

Inter-turn fault
Winding discontinuity
Inter-turn fault

Reactor
Winding discontinuity
Capacitor
Defective rectifier

48 << Operating Instructions Synchronous Generator

Open or short circuit

Reactor

Transformer

Rotor
winding

Exciter

Stator
winding

Rotor
winding

Main
machine

Defective rectifier

Too warm

Stator
winding

On-load
conditions

Genetator
excitation fails

Cause

No load following load duty

Voltage
deviates
from rated
value

Electric fault symptoms

Operating Instructions
Synchronous Generator

4.4 Bearing Part

DANGER
Hazardous voltage
Will cause death, serious injury, electrocution or property
damage.
Disconnect all power before working on this equipment.

Table 4-5. Sleeve bearing

Defects
Possible cause

Bearing Bearing
overheats leaks

Oil
Large
Oil in
discolours temperature
machine
quickly variations

Remedy

Oil aged or dirty

Clean bearing housing; renew oil

Oil ring does not rotate evenly

Straighten and deburr the ring or renew it

Excessive axial thrust or radial load

Check alignment and coupling

Too little crest clearance 1)

Rescrape bearing surface

Oil grooves too small or not wedge-shaped

Refinish the oil grooves

Oil viscosity too high

Check Viscosity; change oil

Oil viscosity too low

Defective bearing surface

Renew lining

Defective seals

Renew seals

Incorrect oil discharge from sealing rings

Clean return openings and grooves

Bearing too cold during start-up

Preheat the bearing or oil

Gap between sealing cover and shaft too large

Bush or replace the cover

Pressure compensation opening clogged

Clean compensation opening

Forced-lubrication system failure

Inspect system

Oil flow too high

Readjust the flow rate; check oil discharge

1) Crest clearance = Inside diameter of bearing shells minus diameter of shaft.

Table 4-6. Roller bearing

Defects
Possible cause

Bearing Bearing
overheats leaks

Remedy

Oil in
machine

Felt sealing rings pressing on shaft

Fit rings better into grooves or replace them

Strain applied from coupling

Improve alignment of machine

Excessive belt tension

Reduce belt tension

Bearing contaminated

Clean or renew bearing, inspect seals

Ambient temperature higher than 40

Use special high-temperature grease

Lubrication insufficient

Lubricate according to instructions

Bearing canted

Check mounting conditions, install outer ring with lighter fit

Too little bearing play

Fit bearing with larger play

Bearing corroded

Renew bearing, inspect seals

Scratches on raceways

Renew bearing

Scoring

Renew bearing, avoid vibration while at a standstill

Excessive bearing play

Install bearing with smaller play

Instruction Manual

>>

49

04

Trouble Shooting

4.5 Operating Procedure & Check Sheet for

Trouble Shooting

Exampls)
Full load zero (0) power factor = 6

droop.

Full load rated power factor (0.8 P.F) = 3.6

droop.

Unit power factor (1.0 P.F) = Generator voltage

DANGER

is not dropped.

Hazardous voltage
Will cause death, serious injury, electrocution or property
damage.
Disconnect all power before working on this equipment.

2) Parallel running (for manual synchronizing)

- After load testing of each generator, start No. 1 single
running and proceed to items

1) Single running

and

of

4.4.1.

- Start No.1 Engine at its rated speed.

- If the synchro scope indicates a synchronized position,

- Adjust No.1 generator voltage to its rated value at

insert the No. 2 circuit breaker carefully.

no-load using reference value setter (V.R), which is

mounted on control panel side. After adjusting the

NOTE

voltage to its rated value, on the check the generator

If synchronization fails, the generator can be damaged by
a transient current.
Please refer to synchronizing instructions of the switch
board maker.

voltage using a digital tester at switch board side.

- Proceed items

and

of 4.4.1 for No. 2, No. 3 and No.

4 generators.
- After completion of the no-load setting, read the
indicated value on the panel and record the results

- Increase the load constantly from zero (0) to a rated

according to Table 4-7.

load.

- Circuit breaker 'ON'.

- Increase the load constantly from zero (0) to a rated load

- Record the results according to Table 4-9.

(as much as possible) and record the results according

NOTICE

to Table 4-8.
- Proceed to items

and

A. Parallel running of No. 3 and No. 4 generator:

The method is the same as No. 1 & No. 2.
B. If the, power factor and KVAR are unbalnced after
completion above the procedure, consult the generator
manufacturer using Table 4-9.

of 4.4.1 for No. 2, No. 3 and

No. 4 generaters.
- In general, the droop compensating method is used for
our generators for parallel running.
Generator voltage should be dropped in proportion to
the magnitude of the load.
Table 4-7. Single running
Item

Ship No.

No. 1

No. 2

No. 3

No. 4

Notes

R.P.M. or Hz
Voltage
After match the no-load voltage of each generator, dont adjust generator voltage (before, during and after parallel running)

Table 4-8. Single running

Item

Ship No.

kW

Volt (V)

R.P.M. (Hz)

Current (A)

Power Factor

Notes

kW
/
/
/
/

Volt (V)

R.P.M. (Hz)

Current (A)
/
/
/
/

Power Factor
/
/
/
/

Notes

EACH
GEN.
(No. 1, 2...)

Table 4-9. Parallel running

Ship No.
Item
No.1 & No.2,
No.1 & No.3,
No.1 & No.4,
each condition.
No.1,
No.2,
No.3 & No.4,

,
,
,
,

,
,
,
,

50 << Operating Instructions Synchronous Generator

,
,
,
,

,
,
,
,

,
,
,
,

,
,
,
,

,
,
,
,

,
,
,
,

,
,
,
,

Operating Instructions
Synchronous Generator

Memo

Instruction Manual

>>

51

HHIS-WZ-RE-005-01 02.07 Designed by SKYdesign

ELECTRO ELECTRIC SYSTEMS

www.hhi.co.kr

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