s

Synchronous Generator
Content of Documentation

Siemens Electric Machines s.r.o.

Drásov 126
664 24 Drásov
CZECH REPUBLIC
http://www.siemens.cz/semd
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Cust. Doc. Nr.: D-208015-01 Revision:
Project code: CMHIMT6024 Type: 1DB 1036-8AY05-Z
Project Nr.: 3208015 Contract-Nr.: 1401069
Serial Nr.: FQ1320801501
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Rev. Title Title Nr.

1 Technical data
1.1 Operating manual 1DB
1.2 Dimension drawing text DR-705359 B
1.3 Operation and maintenance manual of lubricating distribution
1.4 Typical notation for 1D, 1T, 1DV

2 Drawings
2.5 Dimension drawing DR-704122 B
2.6 Connection diagram DR-703716 D
2.7 Shaft inertia DR-703753
2.8 Electrical Data Sheet DR-703491

3 Test certificates
3.1 I+T plan DR-703679 A
3.2 Protocols according to the I+T plan FQ1320801501

4 Instructions and Additional documents

4.1 Logbook of generator
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4.2 DECS 100 Voltage regulator Rev. L

4.3 GEA Circuit cooler -operation and maintenance instruction
4.4 Slide Bearings, Maintenance and Inspection, ext. lubrication, EFZWI
4.5 Slide Bearings, Installation and Operation, ext. lubrication, EFZEI
4.6 Slide Bearings, Maintenance and Inspection, self lubrication, EFEWI
4.7 Slide Bearings, Installation and Operation, self lubrication, EFEEI
4.8 Spare parts list EFULK 22-225
4.9 Bearing drawing EFULK 22-225
4.10 Bearing drawing EFNLQ 14-125
4.11 Spare parts list EFNLQ 14-125
4.12 Lubricants for Slide Bearings-Recommendation
4.13 Probe GPPE-2VP1
4.14 Liquid Level Controller RM4LA
4.15 Current transformers ASK 127.6
4.16 Tightening torques
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Operating manual

Three-phase synchronous generator

Cylindrical rotor
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Type 1DB

G
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3~
Project: CMHIMT6024
Type: 1DB 1036-8AY05-Z

Siemens Electric Machines s.r.o.

Drásov 126
CZ 664 24 Drásov
http://www.siemens.cz/semd

Operating manual, 1DB revision A 2/2014, Project: CMHIMT6024, Type: 1DB 1036-8AY05-Z
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Dear customers,

Now you become the owners of a synchronous generator produced by the Siemens Electric Machine,
s.r.o. It is a product of the company with many-years' tradition that was produced on the basis of operational
experience by a team of experts and skilled workers and which incorporates the latest know-how and
advanced technology. We produce the series of synchronous generators with power output from about 500
to 25 000 kVA, LV and HV options for all usual applications. We will fulfil your special demands on a generator
for special use or arrangement.

Team of company employees

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Operating manual, 1DB revision A 2/2014, Project: CMHIMT6024, Type: 1DB 1036-8AY05-Z page 2/45
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Rev. Revised items Date Name
4.2.6 Fill the bearings with oil – self lubricated bearing
A 03.02.2014 Pochop
4.2.7 Oil cleanliness
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Contents page
1 Generally ............................................................................................................................................. 7
1.1 Significant (relevant) terms ........................................................................................................... 8
1.2 General safety information ........................................................................................................... 8
1.3 Type marking of generators ........................................................................................................ 10
2 Description ........................................................................................................................................ 11
2.1 Technical description, variants .................................................................................................... 11
2.1.1 Machine ends designation ....................................................................................................... 11
2.1.2 Cooling method, ventilation .................................................................................................... 12
2.1.3 Rotor ...................................................................................................................................... 13
2.1.4 Stator ..................................................................................................................................... 13
2.1.5 Bearings ................................................................................................................................. 13
2.1.6 Terminal box........................................................................................................................... 13
2.1.7 Measuring and protective circuits ............................................................................................ 13
2.2 Electric characteristics ................................................................................................................. 13
2.2.1 Output and raise of the temperature ....................................................................................... 13
2.2.2 Short-term current overload .................................................................................................... 13
2.2.3 Voltage ................................................................................................................................... 13
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2.2.4 Shape of a voltage curve ......................................................................................................... 13

2.2.5 Asymmetric load ..................................................................................................................... 14
2.2.6 Short-circuit current ................................................................................................................ 14
2.2.7 Radio interference elimination................................................................................................. 14
2.2.8 Currents in star neutral points ................................................................................................. 14
2.3 Use............................................................................................................................................. 14
2.4 Warranties .................................................................................................................................. 14
2.5 Standards ................................................................................................................................... 14
3 Transport and storage ....................................................................................................................... 15
3.1 Safety recommendation .............................................................................................................. 15
3.2 Indoor and overland storage conditions and recommendations .................................................... 16
3.2.1 If no dry storage condition is available ..................................................................................... 16
3.2.2 Rust protection ....................................................................................................................... 16
3.2.3 Rolling bearings ...................................................................................................................... 16
3.2.4 Sleeve bearings ....................................................................................................................... 17
3.2.5 Anticorrosion treatment of machined parts and bearings ......................................................... 17
3.2.6 Condensation ......................................................................................................................... 17
3.3 Sealed packings .......................................................................................................................... 18
3.4 Inspection during storage ........................................................................................................... 18
4 Installation and operation ................................................................................................................ 19
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4.1 Safety recommendation .............................................................................................................. 19

4.2 Preparation ................................................................................................................................. 19
4.2.1 General inspection of machine ................................................................................................ 19
4.2.2 Locating ................................................................................................................................. 19
4.2.3 Foundation inspection ............................................................................................................ 19
4.2.4 Cooling ................................................................................................................................... 19
4.2.5 Installation of machine ............................................................................................................ 20
4.2.6 Fill the bearings with oil – self lubricated bearing ..................................................................... 20
4.2.7 Oil cleanliness ......................................................................................................................... 21
4.2.8 Connecting the oil supply system ............................................................................................ 21
4.2.9 Connection of cooling piping (air-to-water cooler, cooling lubrication system) .......................... 22
4.2.10 Alignment (rolling bearings) .................................................................................................... 22
4.2.11 Alignment (slide bearings)....................................................................................................... 24
4.2.12 Securing of mechanical position .............................................................................................. 26
4.2.13 Checking the insulation resistance of stator winding ................................................................ 26
4.2.14 Insulation test for stator winding ............................................................................................. 26
4.2.15 Drying .................................................................................................................................... 27
4.3 Electric installation...................................................................................................................... 28
4.3.1 Making the electrical connections............................................................................................ 28
4.3.2 Making the electrical connections............................................................................................ 29
4.3.3 Safeguarding .......................................................................................................................... 29
4.4 First start and operation .............................................................................................................. 29
4.4.1 Installation.............................................................................................................................. 29
4.4.2 Change of rotating direction.................................................................................................... 30
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4.4.3 Operation ............................................................................................................................... 30
4.4.4 Check of operation.................................................................................................................. 30
4.4.5 Safety measures at stationary machine ready for start up ........................................................ 31
4.4.6 Intervals of preventive inspections ........................................................................................... 31
4.4.7 Putting out of operation .......................................................................................................... 32
4.4.8 Operational log ....................................................................................................................... 32
4.5 Diagnostics of defects ................................................................................................................. 33
4.5.1 Mechanical causes .................................................................................................................. 33
4.5.2 Electric causes I ....................................................................................................................... 34
4.5.3 Electric cause II ....................................................................................................................... 35
5 Maintenance ..................................................................................................................................... 36
5.1 Safety recommendation .............................................................................................................. 36
5.2 Five safety rules .......................................................................................................................... 36
5.3 Inspection of insulation condition................................................................................................ 36
5.4 Cleaning ..................................................................................................................................... 36
5.5 Bearing maintenance .................................................................................................................. 37
5.5.1 Antifriction bearings................................................................................................................ 37
5.5.2 Sliding bearings ...................................................................................................................... 37
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5.6 Troubleshooting components on rectifier supporting wheel ......................................................... 38

5.7 Rotating rectifier – inner excitation system .................................................................................. 38
5.7.1 Changing the rectifier diodes................................................................................................... 39
5.7.2 Changing the varistors ............................................................................................................ 40
6 Disassembly and regressive assembly.............................................................................................. 41
6.1 Dismantling and reassembling machines 1D ................................................................................ 41
7 Regulation ......................................................................................................................................... 42
7.1 General description, control principle .......................................................................................... 42
7.2 Range of voltage regulation ........................................................................................................ 43
7.3 Regulation accuracy .................................................................................................................... 43
7.4 Dynamic states of voltage ........................................................................................................... 43
7.5 Parallel operation ........................................................................................................................ 43
8 Neutral wire ...................................................................................................................................... 44
8.1 Generally .................................................................................................................................... 44
9 Generator disposal after lifetime expiration .................................................................................... 44
10 Contacts ......................................................................................................................................... 45
10.1 Customer Service – Manufacturer ............................................................................................... 45
10.2 Service Coordination Center and Industry Hotline – Worldwide .................................................... 45
10.2.1 I CS LS LD - USA territory ......................................................................................................... 45
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List of figures
Fig. 1 Machine ends ................................................................................................................................... 11
Fig. 2 Closed circuit .................................................................................................................................... 12
Fig. 3 Open circuit ...................................................................................................................................... 12
Fig. 4 Transport of machine ........................................................................................................................ 15
Fig. 5 Example for axial shaft blocking ....................................................................................................... 17
Fig. 6 Humidity indicator ............................................................................................................................ 18
Fig. 7 Transport bracing.............................................................................................................................. 20
Fig. 8 Oil level schematic description .......................................................................................................... 21
Fig. 9 Optimal oil level ................................................................................................................................ 21
Fig. 10 Example of flanges flexible connection ............................................................................................ 22
Fig. 11 Checking the alignment of shafts .................................................................................................... 23
Fig. 12 Axial alignment of the rotor in D-end bearing .................................................................................. 24
Fig. 13 Example of axial measurement, view of measuring points at DE ...................................................... 24
Fig. 14 Measuring points for radial alignment ............................................................................................. 25
Fig. 15 Recommended stator terminal arrangement.................................................................................... 28
Fig. 16 Assembly kit for rectifier wheel with diodes (illustrative only) .......................................................... 38
Fig. 17 Diodes assembly (seen from collector rings side) ............................................................................. 39
Fig. 18 Varistor assembly............................................................................................................................ 40
Fig. 19 Dismantling and reassembling......................................................................................................... 41
Fig. 20 Regulation ...................................................................................................................................... 42

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List of tables
Tab. 1 Oil cleanliness requirements ............................................................................................................ 21
Tab. 2 Deviations ....................................................................................................................................... 23
Tab. 3 Permissible deviations ...................................................................................................................... 25
Tab. 4 Minimum value of insulation resistance ............................................................................................ 26
Tab. 5 Tightening torques for screwed electrical connections ...................................................................... 28
Tab. 6 Minimum air distance ...................................................................................................................... 29
Tab. 7 Visual inspection of the machine ...................................................................................................... 29
Tab. 8 Mechanical causes ........................................................................................................................... 33
Tab. 9 Electric causes I................................................................................................................................ 34
Tab. 10 Electric causes II ............................................................................................................................. 35
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1 Generally
Herein submitted operational instructions refer only to standard type. Possible dissimilarities from standard
model (special models) are described in enclosures or supplements of operational instructions.

NOTICE: Contents of operational instructions and production documentation is not the part of previous or
current agreements promises or juridical relations or is not to change above mentioned. All obligations of
SIEMENS result from existing purchase contract that also contains complete and valid delimitation of
warranties. These contractual warranty contracts are neither limited nor extended by elaboration of these
instructions and documentation.

Danger
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Electric machines are operational

devices to be used in industrial heavy-
current machinery. In the course of
operation these operational devices
have dangerous voltage, conductive
bare parts, moving or rotating parts.
Therefore they can cause the worst
injuries or damage to properties in
case of inadmissible removing of
covers, unprofessional handling,
incorrect manipulating or insufficient
maintenance.

Therefore the workers responsible for safety operation of a

device have to secure the following:
- only qualified operators have to be authorised to attend these
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machines
- these operators and the others must always have submitted
operational instructions and the other production
documentation at their disposal in the course of all
corresponding operations and have to adhere to this
documentation consistently.
- unqualified people are forbidden to operate the machines
and keep in their surrounding.!!!

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1.1 Significant (relevant) terms

Warning terms such as DANGER, WARNING, CAUTION and RECOMMENDATION which are mentioned in
this operational instructions are used to inform about danger or extraordinary information that require special
marking.

DANGER means that in case a person does not adhere to it, his life can be jeopardised or he may cause
damage to property.

WARNING means that in case a person does not adhere to it, he may induce difficult injury or cause damage
to property.

CAUTION means hat in case a person does not adhere to it, he may induce an injury or cause damage to
property.

RECOMMENDATION means that there are extraordinary and special technical connections that are not
obvious even for experts.
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Regardless, it is also necessary to adhere to recommendations that are not specially emphasized,
regarding transport, operation and maintenance as well as technical data (which are given in operational
instructions, production documentation and on the machine itself) to prevent breakdown which can either
directly or indirectly induce difficult injuries of people or cause damage to property.

Qualified staff are operators who were in charge of safety of device, who are able to perform all
necessary activities and at the same time recognize and prevent possible danger. These operators have to
perform above mentioned as the result of their education, experience, previous training as well as acquiring
knowledge of standards, provisions, regulations, safety of work and working relations.
Above all qualification of staff providing service and maintenance has to correspond to the laws
concerning work on heavy-current devices of a particular country which the device is operated in.
Besides, knowledge of provisions of first aid and local rescue devices is necessary as well.
Concerning work on heavy-current devices, restriction of employing unqualified people is determined
in e.g. IEC 60364-4-41:2.

1.2 General safety information

Herein mentioned machines are parts of heavy-current devices for industrial extent of use. They are
produced in compliance with corresponding and acknowledged technical regulations.
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WARNING: It is supposed that basic planned operations with a device as well as all operations concerning
transport, assembly, installation, launching, maintenance and repairs will be performed by qualified staff or
checked by responsible experts.

Concurrently it is necessary to take the following into consideration:

Technical data and data of admissible use (assembly connection terms, environmental terms and operational
terms), which are, among others, stated in a catalogue, in operational instructions, orders, name plates and in
the other technical documentation.

General establishing and safety provisions. Local provisions and requirements which are specific for the
device. Qualified use of tools, lifting and transport devices. Use of personal protective devices.
Duty of responsible people to take part in training on safety of employees in accordance with SAFETY
PROVISIONS as well as keeping to the laws of a country in which the device is operated. Above all the laws,
concerning protection of environment, handling with waste, safety use of substances that are dangerous for
lives or environment e.g. cleaners, lubricants, adhesives, varnishes etc. Detailed information about these
special products can be found in a “list of safety data” provided by producers or importer of a product.

Operational instructions cannot contain all detailed information concerning different construction variants
and cannot take into consideration every possible occurrence of installation, operation or maintenance owing

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to the loss of lucidity. Therefore operational instructions designed for qualified operators (see above
mentioned) contain such recommendations that are necessary if a machine is used in accordance with
provisions in the extent of industrial operation.

If there are special requirements concerning nonindustrial area (e.g. protection against dangerous
touch of children fingers and so on), these conditions have to be secured on the device by means of
supplementary protective provisions.

If there are any discrepancies, especially missing information which specify a product, sales department of
SIEMENS is in charge of providing necessary explanation. Concerning this matter we ask you to mention
mainly type and production number of a machine, please.

Concerning planning, assembly, launching and service we recommend using the promotion and
services of appropriate service centre of SIEMENS.

RECOMMENDATIONS: Other detailed information concerning general works e.g. checking of delivered coils
(damages which can be caused during transport), long term storage and preserving of machines, checking of
footing, connection stretching, erection (setting) and (seating), levelling of a machine and others could be
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found in our “Assembly materials” or (newly) in “Operational instructions”. These materials could be obtained
in SIEMENS sales department.
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1.3 Type marking of generators

1 D B 06 24- 4 A V 03 -Z
Synchronous machine D

Rotor type Number of pole pairs

cylindrical rotor B
salient pole rotor C Stator frequency and voltage
Hz/kV
cylindrical rotor, steam and gas turbine U
B 50/ <6.3
Salient pole rotor, water turbine H
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Salient pole rotor, piston machine K C 50/ 6.3

D 50/ 6.3 - 11.0
Diameter of stator core (coded) E 50/ 11.0
Standard frame size just For 1DB, 1DC F 50/ >11.0
400 mm frame size 03 H 60/ <4.16
450 mm frame size 04 J 60/ 4.16
500 mm frame size 05 K 60/ 4.16 - 6.6
560 mm frame size 06 L 60/ 6.6
630 mm frame size 08 M 60/ 6.6 - 13.8
710 mm frame size 10 N 60/ 13.8
800 mm frame size 12 P 60/ >13.8
V 50/≤0.5
Length of stator core (coded)
W 50/≤1.0
X 60/≤0.5
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Degree of protection Y 60/≤1.0

IP 00 0
IP 11 1
IP 20 2 Mounting and Ex-protection
IP 21 3 A IM B... no Ex-protection
IP 23 4 B IM B... E(Ex) p
IP W24 5 C IM B... E(Ex) n, E(Ex) e
IP 44/54/55/56 Tube 6 D IM 7… no Ex protection
IP 44/54/55/56 CACA 7 E IM 7… Ex protection
IP 44/54/55/56 CACW 8 F IM B… Eex n, e

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2 Description

2.1 Technical description, variants

Machines series, 1D are three-phase brushless synchronous LV and HV generators with a cylindrical rotor.
They consist of an AC generator (main machine) and an exciter with rotating rectifier. Main machine and
exciter rotors are fitted together with rotating rectifier and fan on the same shaft. Voltage regulating parts are
located in a terminal box or belong to machine supply being installed in switchboard. All these parts form a
compact component along with welded cover and bearings.

2.1.1 Machine ends designation

For a clear description machine ends are designated as follows (Fig. 1) DE side being at free shaft end
where generator drive is connected. Machine sense of rotation is defined when viewed from this machine
side. The other machine side is designated as NDE with no shaft outlet; also exciter with rotating rectifier are
mounted here.
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DE NDE
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Fig. 1 Machine ends

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2.1.2 Cooling method, ventilation
Ventilation method is based on operating conditions and client’s demands. Machine cooling proceeds by
two methods: in the first one open ventilation system (Fig. 3) sucks ambient air to cool the winding, warmed
air is exhausted by fan to the atmosphere on AS side. The other cooling method makes use of internal cooler
(Fig. 2). It is a closed circuit air-circulation system, in which air is cooled in a water or air cooler and returned
back to the main machine. This system is applied if a higher degree of protection is required.
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1 Rotor
2 Stator
3 Fan
4 Cooler
5 Housing top

Fig. 2 Closed circuit

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1 Rotor
2 Stator
3 Fan
4 Housing top

Fig. 3 Open circuit

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2.1.3 Rotor
Main machine and exciter rotors are fitted together with rotating rectifier and fan on the same shaft.
Generator rotor is a compact component with cylindrical and a squirrel-cage damper in a magnetic field. The
rotor itself is supported by two bearings and is extended at the drive end. It is press-fitted on the shaft and
excited by an integrated exciter. Exciter rotor with plain poles is mounted on machine NDE side. Rectifier in
rotor circuit is fitted inside the machine on NDE side.

2.1.4 Stator
Main machine stator consists of a welded chassis in which a stator bundle is press-fitted and locked against
rotating. Stator bundle has a stator-sheet core, a main and auxiliary winding. Exciter stator is mounted in the
end shield on machine NDE side and is of a pole type. It is provided with permanent magnets intended to
excite the machine during starting.

2.1.5 Bearings
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Generators are equipped with antifriction of slide bearings with relubrication and grease amount
regulator. They are fitted in end shields. On request also plain bearings are mounted. In this case operating
instructions are complemented by a detailed description incl. operation. One of the bearings is insulated in
order to prevent a shaft current and to protect the bearing shells.

2.1.6 Terminal box

Main winding spacious terminal box is fitted on the top of generator stator box. It contains all equipment
necessary for generator connection and operation. Standard generator model is supplied with an unbored
cable entry plate. PG screwed cable entry glands can be supplied on request. Regulation and measuring
circuits are always led to an independent LV terminal box.

2.1.7 Measuring and protective circuits

Generator is standard equipped with (if not otherwise requested): temperature sensors Pt 100 in stator
winding, bearing thermometers Pt 100 or 2xPt 100 in bearing caps, probes for mounting heating bodies.
On request sensors of internal air temperature and cooler water see page can be fitted.

2.2 Electric characteristics

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2.2.1 Output and raise of the temperature

Determined output that is stated on the name plate is intended for long-term operation with symmetrical
load, prescribed frequency and voltage, power factor cosϕ = 0,8 to 1,0, ambient air temperature according to
requirement and altitude of machine location up to 1000 m. Simultaneously, the machine is used in
compliance with temperature class (155) F according to IEC 60034-1.

2.2.2 Short-term current overload

Machines can bear short-term overload according to IEC 60034-1.

2.2.3 Voltage
Machines are standardly supplied with a star connection for voltage according to machine name plate.
ATTENTION!! Machines can be operated at voltage according to machine name plate.

2.2.4 Shape of a voltage curve

Time behaviour of terminal voltage during idle running and during symmetrical linear load is virtually
sinusoid with upper frequency response according to IEC 60034-1.

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2.2.5 Asymmetric load
Asymmetric load according to IEC 60034-1-22

2.2.6 Short-circuit current

During symmetrical three-phase short-circuit the value of short-time short-circuit current makes minimally
triple of nominal current. Short-circuit current must be switched off within 3 s.

2.2.7 Radio interference elimination

Generators correspond to interference elimination degree according to IEC 60034-1.

2.2.8 Currents in star neutral points

If star neutral points of generators are connected mutually or with neutral points of transformers and
appliances directly, then transient currents with triple determined frequency could appear in conductor
among neutral points. To prevent thermal jeopardy of generators, transient currents should not exceed 50 %
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of nominal current of generator. Higher currents should be reduced outside of device by means of current
limiting choke or similar devices.

2.3 Use
Generators are used in land central offices and in naval shipboard networks for long-term or reserve
operation. They can be driven by combustion engines, gas of water turbines or electromotors. They can run
individually, parallelly with similar device or it is possible to connect them to public network.

2.4 Warranties

Warranties refer to adhering of operational instructions and permissible operational terms. If these
provisions are not adhered, it can result in refusing of warranty claims. During claim or with spare parts order
it is necessary to provide factory (production) number and if need other data stated in output name plate. The
user is obliged to keep the operational log, and he can dismantle the generator only if approved by the
producer otherwise the producer shall be released from the obligations under its warranty. During the
warranty and after the warranty period, the user must not make any external and internal intervention in the
machine design.
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2.5 Standards

Generator design corresponds to standards IEC 60034-1. If required, generators can meet requirements of
other standards and regulations.

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3 Transport and storage

3.1 Safety recommendation

! WARNING. During any lifting or transport of an aggregate it is necessary to use only openings that are
provided for lifting and transportation, gripping lugs or pins in foundation plate! Lifting should be performed
for axially symmetrical places at least see (Fig. 4). Aggregates must not be lifted hanging on individual parts
of a machine! Existing accessory lifting lugs e.g. on bearing shields, cooler superstructure etc. are provided
only for lifting of these individual parts of the machine.
Lifting capacity of applied lifting device should be taken into consideration! Lifting devices should be
chosen with respect of the weight of machine. Appropriate guiding of ropes should be used with possible
superstructures or extension.
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Fig. 4 Transport of machine

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3.2 Indoor and overland storage conditions and recommendations
Generator and its accessories must be professionally stored before installation if necessary. They must be
protected from humidity, harmful environmental conditions and from other strange influences. Dew point
level must not be reached because of corrosion. If the machine is placed in a transport box, it must be
removed out of it before storage.
Storage areas must be clean, dry, closed, properly ventilated and protected from tremors. Conditions shall
be ensured by compliance with the following recommendations:

Room climate
1st condition
• The relative humidity must be kept below 50%
• Temperature ranges for storage must be between 10 to 50˚C, dew point temperature will never be
achieved

2nd condition
• Where the first condition of storage can´t be observe, it is necessary to observe the following
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conditions: Temperature inside the storage area = (outer temperature + 10°C)

Outer conditions
CAUTION

Only seal packed machine may be store outside for storage period. Seal packaging must be
undamaged. For the storage conditions to be applicable for outside storage, observe the
information’s in “Storage of motors and generators” manual.

• The relative humidity must be kept below 80%

• Temperature ranges for storage must be between -5 to 50˚C

Generator is prepared for 6 months storage after dispatch from the factory to the customer. In the case of
long term storage, more than 6 months, some requirements such as protection of bearings, extended shaft
end, foots or sealed packing with dehumidifiers, etc must be taken into consideration for proper functioning
after storage. For some additional information about long term storage of entire machine or its parts
(bearings, etc) please ask Siemens Electric Machines s.r.o (see chapter 10) for manual Storage of motors and
generators.
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3.2.1 If no dry storage condition is available

- air-tight film packing
- bags with hygroscopic material inside film
- humidity indicator inside film
- regular inspections

3.2.2 Rust protection

- All accessible bright arts (e.g. shaft extension, flange, feet) have a protective coat for 6 months storage
under dry condition

- for longer storage time all accessible bright parts have to be provided with a long-term anti-corrosion
coating (e.g. plastics lubricant LV 2-3 )

- regular inspections and repeated anti-corrosion coating if necessary

3.2.3 Rolling bearings

- The rotor of generators with cylindrical roller bearings or single angular-contact ball bearings has to be
axially locked to prevent bearing damage

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- don´t remove shaft blocking (Fig. 5) fitted by SIEMENS (rotor shipping brace) or remount it after no
load tests

- if shaft block was removed to fit the transmission element (coupling, belt pulley), other measures for
shaft blocking have to be ensured

Fig. 5 Example for axial shaft blocking

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3.2.4 Sleeve bearings

Sleeve bearings are generally delivered without oil !
- generators should be stored also without oil filling
- shaft bearing journals are provided with an anti-corrosion oil film which dissolves in lubrication oil
during operation
- delivered corrosion oil film protection is designed for a storage life of half year under dry condition
(3.2)
- for longer storage bearings have to be disassembled and bearing journals and parts have to be provided
with a long-term protection coat.

3.2.5 Anticorrosion treatment of machined parts and bearings

WARNING

Anticorrosion treatment of slide bearings

Slide bearings must be always treated against corrosion before storage and transportation. In case of
doubts or additional question contact Siemens Electric Machines a.s..
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You can find contact in chapter 10.

3.2.6 Condensation
- Generator with protection class IP54 or higher can be provided with condensate drain holes closed by
plastic plugs.

- the environmental conditions (e.g. big temperature fluctuations) may require the removal of these
plugs. The nominal degree of protection will then be only IP44.

- if installed in generator, the anti-condensation heater should be connected to mains (not necessary, if
you have a dry, well ventilated and air-conditioned storage room).

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3.3 Sealed packings
Sealed packings are used for delicate components and for storage of goods in outside conditions.
In contrast to standard packings, machine parts are completely enveloped in plastic foil wrappings whose
seams are welded to make an air-tight seal. As much of the air as possible inside the foil wrapping is first
removed by suction. The amount of desiccant to be enclosed is calculated for the specified duration of
transport and storage, taking into account the climatic zones involved. All sharp corners and edges are
padded to prevent the wrapping from ripping.
All cases should be subjected to an immediate visual inspection on arrival to make sure the packing, the
contents and the seals are undamaged. If humidity indicators have been provided, the sealed packings must
be inspected visually 1 to 2 days after storage.

Important! If cases have been opened in the ports of arrival and the sealed wrappings have been damaged or
if cases have been damaged during transport, the sealed wrappings must be repaired as quickly as possible (if
possible) in order to ensure proper storage, especially in tropical areas. Opening or damage to the wrappings
must be recorded in writing and immediately reported to the project manager/site supervisor.
If humidity indicators (Fig. 6) are provided in the sealed wrapping, there is an inspection opening in the
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external packaging, the cover of which can be unscrewed. Humidity indicators change their colors from blue
(dry) to pink (damp) to indicate the humidity level (relative humidity) within the sealed plastic wrapping.

Fig. 6 Humidity indicator

Important! Humidity indicators recondition themselves automatically, i.e. they do not indicate whether the
humidity inside the packing was too high at an earlier time.
The accuracy of the humidity indicators depends heavily on the temperature. When the ambient temperature
is 20° C, they are sufficiently accurate but, at other temperatures, the humidity levels they indicate are too
high.
If the relative humidity rises above 60 %, a check must be made to make sure that the contents and the
packing are undamaged. To do this, open the case carefully and check the contents for corrosion.
The date of initial conservation as well as the expiry date is marked on the cases.
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Date of initial conservation: Month Year

Expiry date: Month Year

Check the effectiveness of sealed wrappings every 8 weeks if no other intervals have been specified.
The results of such inspections must be recorded. Cases in which the relative humidity has risen rapidly or
stayed at a high level must be checked.

In case of oil lubrication system, make a connection of oil pumps and connect motor
of oil lubrication system to power supply according to motor rating plate.
Make sure that the rotation corresponds with the arrow on the motor.
For further information see manuals in customer’s documentation.

3.4 Inspection during storage

If storage takes more than 3 months, insulation resistance and preservative coats must be inspected every 8
weeks. If the value of insulation resistance drops down below the value determined in point 4.3.1, table 1,
generator must be desiccated immediately.

You are obliged to record the start/end date of the storage period including all activities performed with the
generator during this period to the operational log of the generator.

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4 Installation and operation

4.1 Safety recommendation

! WARNING Strictly adhere to ”General safety information”, please. In paragraph 1.2 of this Instructions,
recommendations concerning admissible use of machine and recommendations concerning required
professional knowledge that is necessary while operating heavy-current machinery.

Coverings must not be opened during operation (see also paragraph 5). Covers prevent from touching of
active or rotating parts or they are necessary for right routing of air and effective cooling.

For safety reasons, the machine can be started until the coupling is inserted at the free shaft end or after
dismantling the key at the free shaft end.

No higher speeds cannot be adjusted because this is ensured by right designed controlling and checking of
speeds. The only admissible speeds are these that are given according to output name plate.
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4.2 Preparation
4.2.1 General inspection of machine
Generator must be properly inspected prior to erection (installation) with the aim to find out if there are
any damages caused during transport or storage. Any imperfections that are found out must be reported to a
supplier or transport company and must be professionally repaired. Remove preservative coating from metal
surfaces (feet, flange, free end, etc.) prior to machine seating and installation.
Insulation resistance must be inspected. Record the data measured to the operational log.

4.2.2 Locating
Generator must be located in the way that terminal box, bearings and accessories could be easily
approachable.

4.2.3 Foundation inspection

Before installing the machine, carefully check all foundation dimensions with the aid of the machine
dimension drawing and the foundation drawing, particularly - where applicable the positional accuracy of the
holes for mounting the machine on soleplates, the ducts for piping and cable.
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Soft Foot Check The test conforms to API 541-4.3.1.15

The test is made to see if there is any bending of the base frame while fixing the mounting bolts.
Prior to any mechanical running test, a check for "soft feet" will be made.
After the machine has been aligned, shimmed, and firmly secured to the test base, a dial indicator micrometer
oriented in the vertical direction shall be attached at the mounting foot to be checked.
The micrometer is then zeroed, the mounting bolt or bolts loosened at the foot and the change in micrometer
reading noted. If the micrometer reading exceeds 0.025 mm, the mounting requires cleaning or re-shimming.
This soft foot check shall be performed at each mounting foot, with the other feet secured, until all
micrometer change readings are less than 0.025 mm. If there are intermediate bases, this check shall be
performed at each interface between the machine and the test floor.
During the shop running test of the assembled machine, vibration measurements will be made with the
machine properly shimmed and securely fastened to a massive foundation or test floor stand. Elastic mounts
are only used if they are available.

4.2.4 Cooling
Space, in which generator is situated, must be sufficiently large and aired. Generator cannot suck warm air
from other machine. For continuous operation, it is necessary to provide a steady cooling air ventilation with
a volume rate according to Text of dimension drawing.
ATTENTION Temperature on surface parts of electric machines (stator housing, shields) can reach over
100oC, therefore possibility of touching these surfaces must be prevented. At the same time it is forbidden to
put or attach any parts that are temperature sensitive such as normal leads or parts of electronic equipment.

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4.2.5 Installation of machine
Remove the transport bracing 1 (Fig. 7).

1 Transport bracing
2 Hexagonal bolt
3 Bearing

Fig. 7 Transport bracing

Remove preservative from the machined surfaces. No metallic objects, such as scraper, trowel or metal strip,
are to be used for this purpose. Simply wash the preservative off with kerosene or a similar solvent (e.g. Aral
4005 oder Shell A151). The bearings do not have to be opened, since the preservative inside the bearings is oil-
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soluble.

Generator must be placed on a solid foundation without any vibrations. Machine feet must stand on flat
metal base. If need, contact surface must be carefully laid under to prevent deformation of stator body.
When installed, it is recommended that the increase of the axial height of the loaded generator must be
taken into account. The increase of the axial height is affected by the heat machine use (its classification), the
method of ventilation, the generator size, etc.

The most suitable way is to operate the drive until the steady operational temperature regime is achieved,
then to switch off the machine and to make the axial height correction.
The informative calculation of the above-mentioned increase can be done from the following formula: Height
increase [µm] = 0.312 x vertical foot distance from the shaft axis.
Keep a record in the operational log.

4.2.6 Fill the bearings with oil – self lubricated bearing

For further information, see Manufacturer's "Instructions for Maintenance and Inspection" in the machine
handbook. Use only the oil specified in the text to the dimension drawing, or on the type plate on the bearing.
If there is no information about the oil observe information in chapter 4.2.7 Oil cleanliness.
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Bearing with self lubrication must be filled so that the bearing is sufficiently lubricated and it´s prevented oil
leakage and seizure risk. Oil level must be set precisely according to information in this chapter.

CAUTION
Filling procedure
Use filling procedure for bearings with self lubrication prior to the procedure from bearing manufacturer.

Oil temperature has to be set according to oil manufacturer before bearing filling (lower temperature -> higher
oil viscosity). Observe storage conditions on the oil package.

DANGER
Non conformity to instruction mentioned in this chapter can cause bearing brass or bearing damage during
operation.

General procedure for oil filling for self lubricated bearing, see Fig. 8 and Fig. 9

- Remove the screw plugs from the oil filling hole. Keep the filling hole clean and free of any particles.
- Use a lubricant with the viscosity indicated on the bearing type plate or in dimension drawing text.

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- Fill the lubricant through the oil filling hole on the upper side to the first third of the oil sight glass
(position of the sight glass is described in manufacturer instruction of the bearing).
You can also use this formula: Oil volume = Volume of the bearing tank – 2 liters.
- Wait for min. 10 minutes. Oil fills up inner bearing space and sight glass slowly.
- Add precisely the remaining oil to reach the requested oil level, see Fig. 8 and Fig. 9.
- Put the scruw plug back and tighten it.

The oil level limits are as follows:

Minimum oil level: bottom third of the sight glass

Maximum oil level: half of the sight glass

Sight glass oil volume Result

Level 1 <1/3 Bearing seizure risk
Level 2 1/3 – 1/2 Requested oil level
Level 3 >1/2 Oil leakage risk
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Fig. 8 Oil level schematic description Fig. 9 Optimal oil level

4.2.7 Oil cleanliness

If nothing different is specified in the dimension drawing text, use oil with oil purity code (ISO 4406 or NAS grade
standards) according to Tab. 1. If there is specified different purity code of oil in the dimension drawing text, the
purity code in the dimension drawing text must be used as preferred.
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Specification ISO code NAS code

ISO number/NAS grade ISO 17/15/12 NAS6

Tab. 1 Oil cleanliness requirements

4.2.8 Connecting the oil supply system

All the information required on the connection of the oil supply system to the bearings can be found in the
machine dimension drawing / dimension drawing text and in the instructions provided by the manufacturers
of the bearings and the oil supply system. Further, you should also observe the following information.

1. Make sure that the thermometers of the insulated bearing do not jumper the bearing insulation.
2. Close all unused drill holes with screw plugs. Exception: The atmosphere connection remains open.
3. Route the pipes so that no loads or vibration can occur at the bearing housing connections.
4. Flush the oil-circulating system prior to installation of the oil pipes until only clean oil comes out. To do this,
use the quality of oil as specified for use later in operation.
5. Make sure that the oil supply system operates for a sufficiently long time before the motor starts and
continues to operate for some time after the motor stops. This is how you avoid the bearing running dry
when the motor accelerates and decelerates.
6. Connect the oil supply system to the bearings.

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4.2.9 Connection of cooling piping (air-to-water cooler, cooling lubrication
system)
Connection between flanges on the water coolers or lubrication oil devices must be done by using flexible
element (see Fig. 10) due to mutual interactions between two independent piping. Flexible element avoid
relieve movement stress, reduce noise, isolate vibration, compensate for misalignment during machine
operation.

Requirements for coolant piping:

- Ensure that the coolant lines are routed and supported so that the connection flanges are not exposed
to stress, strain or vibration loads.
- The required data for the connection flanges are given in the machine dimension drawing/dimension
drawing text.
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Fig. 10 Example of flanges flexible connection

4.2.10 Alignment (rolling bearings)

CAUTION
Clutch cover – alignment of generator (motor) with drive machine
Alignment of electric machine with drive machine and covering the clutch must be done this way,
that clutch together with cover never create negative pressure on the front side of the bearing. In the
case you do not keep this condition it can happen oil taking from the bearing, oil leakage and
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dripping through bearing seals.

Flexible connections must be used to connect generator and driving machine mechanically. The coupling
must transmit only torsion moment from driving machine that must get rid of impact peaks that are produced
especially by combustion engines. Further, it must attenuate all axial and radial vibrations of driving machine.
Coupling must be dynamically balanced, it itself must not be a source of any undesirable forces and
vibrations.

The thermal expansion of the shaft in axial and radial direction for the machine specified in the manual
“Dimension drawing text”

That extension should be considered in motor clutch system design.

For additional information see Annex, or contact us.

Prior to assembly of connection on the generator shaft, preservative coat must be removed and the shaft
should be slightly varnished with oil. Concerning actual assembly of a installation on the shaft, it is
recommended to use assembly jig that will fit in a thread in generator shaft.
Coupling must not be pulled on shaft by force.
When pulling down the connection from the shaft, it is necessary to use pulling jig.

WARNING
It must be ensured that in mounting and dismounting the coupling was not damaged drive shaft end.

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When connection the generator with another machine is to be ensured that the shaft of both machines are
aligned. Frontal plane of both coupling mounted on the machine shaft must be exactly perpendicular to the
axis.

4.2.10.1 Shaft alignment

Alignment of the shafts for the establishment of machinery based on setting and check according to (Fig. 11),
so that the measured indicator or other suitable device dimensions A and B at 0°, 90°, 180°, and 270° (0°,
120°, 240° hampers the base), while rotation of the coupling halves (Fig. 11).

Coupling of a set must be adjusted by means of two indicators or another appropriate device according to
(Fig. 11) . Tolerance that is determined by a producer of connection should be reduced as much as possible
because every slightest defect will cause disproportionate increase of burden on bearings and coupling. Check
the coupling during the steady operating temperature, and record the parameters to the logbook.
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Fig. 11 Checking the alignment of shafts

Deviations of dimensions A and B measured at different positions may be greater than (see Tab. 2)

Diameter of flange coupling (mm) Deviation (mm)

to 250 0,02
over 250 to 400 0,03
over 400 0,05

Tab. 2 Deviations
4.2.10.2 Alignment of the coupling
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Any differences in the height adjustment clutch is aligned under the machine feet inserts appropriate shapes
made from sheet steel.
After alignment of the coupling halves and tighten the machine screws fixing the base must be the coupler
checked.

Manufacturer’s tolerances connections should be reduced as much as possible, because the slightest glitch
can cause a disproportionate increase in load bearing and coupler.

CAUTION
After starting the machine, and after reaching operating temperature machines (sets), it is necessary
to again check run out of the coupling halves according to paragraph 4.2.9.1
Failing to values listed in Tab. 2 it is necessary to make a correction according to 4.2.9.2.
Measured parameters recorded in a logbook.

CAUTION
Imprecise mechanical connection of the both machines, sets vibrates and roared, damaging the
coupler and bearings.

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4.2.11 Alignment (slide bearings)

CAUTION
Clutch cover – alignment of generator (motor) with drive machine
Alignment of electric machine with drive machine and covering the clutch must be done this way,
that clutch together with cover never create negative pressure on the front side of the bearing. In the
case you do not keep this condition it can happen oil taking from the bearing, oil leakage and
dripping through bearing seals.

Careful alignment with the machine to be driven is essential for smooth running and trouble-free operation of
the machine set.
The generator is aligned with the already trued-up and securely mounted motor. Written confirmation of the
proper alignment of the motor and correct positioning of the coupling flange (height) must be obtained.
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When making the axial alignment, bear in mind that the rotor is guided axially in the D-end bearing (see also
dimension drawing/text). A symmetrical position of the shaft in the bearing shell must be ensured during
alignment. For this purpose, determine the dimension of rotor deflection (Fig. 12) by moving the rotor axially
towards the D end and then the N end until the right and left shaft shoulder respectively make contact with
the bearing shell. The mean deflection is then determined on both sides of the bearing shell.

Fig. 12 Axial alignment of the rotor in D-end bearing

Measure the axial offset between the coupling halves at four points 1, 2, 3 and 4 spaced evenly round the
circumference (for example see Fig. 13). Make a note of this first measurement.
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Measuring point
1 2 3 4
1. Measurement: 95 92 85 100
2. Measurement: 95 92 90 100
3. Measurement: 93 87 85 102
4. Measurement: 100 95 98 98
Mean: 97 91,5 89,5 100

1st evaluation 2st evaluation

Deviation in vertical plane 0,0375 mm Deviation in horizontal plane 0,0425 mm

Fig. 13 Example of axial measurement, view of measuring points at DE

Repeat and note the measurements after rotating both shafts (together as far as possible) through 90° to the
positions 90°, 180° and 270°.

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IMPORTANT
Measuring point 1 is always at the top; i.e. the notional measuring cross is not rotated.

Calculate the mean values for the four measuring points. Measure the radial off-set between the coupling halves
at four points 1, 2, 3 and 4 distributed evenly round the circumference (Fig. 14) and make a note of the values
measured.
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Fig. 14 Measuring points for radial alignment

Determine the deviation for axial and radial off-set () from the values measured at opposite measuring points
(points 2 and 4 for the horizontal plane, and points 1 and 3 for the vertical plane).

Depending on the deviations, the machine is to be shifted as follows vertically by removing or inserting shims
under the feet of the machine horizontally by sliding the machine sideways. These operations are to be repeated
until the axial and radial off-sets are within the permitted deviations.

Permissible deviations Radial off-set mm Axial off-set mm

Rigid coupling 0,03 0,02
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Flexible coupling 0,05 0,05

Tab. 3 Permissible deviations

Coupling acceptance
Coupling acceptance is to be carried out in the presence of representatives of the customer and of the manufacturer of
the driven machine.
A written record should be kept of the results of the coupling inspection.
Test the direction of rotation before coupling the machines.

The coupling halves should be coupled in accordance with the coupling manufacturer's instructions.

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4.2.12 Securing of mechanical position
The right position of installed and fixed generator to the foundation must be secured in such a way that
set axial alignment will not be changed in the course of operation. Feet must be plugged in into the
foundation.

4.2.13 Checking the insulation resistance of stator winding

• Measure the insulation resistance of the stator winding with respect to the stator core and enclosure prior to
commissioning or after prolonged non-operational periods (due to storage or standstill, for example).
• Perform the test in accordance with IEEE Std 43 "Recommended practice for testing insulation", see
chapter 4.2.14.
• Use a suitable insulation tester.

CAUTION
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Before you begin measuring the insulation resistance, please read the manual for the insulation
resistance meter you are going to use.

• Where possible, measure the insulation resistance of the winding with respect to the machine enclosure when
the winding temperature is between 20 and 30 °C.
• When making a measurement, wait until the measuring instrument display no longer changes. This will take
approximately one minute.

4.2.14 Insulation test for stator winding

Before the first commissioning, or after prolonged storage or standstill periods, it is necessary to measure the
resistance of the stator winding to the stator laminations and frame.
It is generally sufficient to conduct this measurement with an insulation test device, such as a megger.
Recommended measuring voltage: 1000 V
Measuring connection: All phases tested together against iron, connection cable and instrument transformer
disconnected.
Minimum value of insulation resistance:
R 40°C>=10*(UN +1) M Ω (1-min-value) 1)
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Un = numerical value of rated voltage in kV

1) Following IEEE 43

Temperature correction: Halving/doubling of the resistance value is to be expected with temperature increases
/decreases of 10 K.
The values below must be achieved during the measurement.
R50°C ≥ 14 MΩ
R40°C ≥ 28 MΩ
R30°C ≥ 55 MΩ
R20°C ≥ 110 MΩ
R10°C ≥ 220 MΩ
Tab. 4 Minimum value of insulation resistance
Conducting the test:
• Set up measuring connection, with the winding still earthed
• Measure the winding temperature with the built in temperature sensors
• Remove earth connection
• Switch on insulation test device and take a reading after one minute
• Switch device off
• Earth winding

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Insulation test for excitation and low-voltage windings
To avoid damaging the semi conductors, these have to be short-circuited. All connections of the semi conductors have
to be connected to their heat sinks, i. e. the clamping covers.
Low-voltage windings of MICALASTIC design are to be tested essentially the same as high-voltage windings. Since
insulation resistance can reach k Ω values in the presence of high temperatures, it is advisable to take measurements
with voltages <500 V, for example 100 V. The insulation resistance of rotor windings is measured against the earthed
shaft.
When in operation and at normal operating temperature, excitation windings should have an insulation resistance of
not less than 0.1 M Ω . If not, the windings should be cleaned or dried. Particular care should be given to the exciter
connection on the shaft and the pole connections in the stator of the brushless exciter.
At room temperature, new exciters should have an insulation resistance per pole of Ris >200 M Ω . For the
complete winding, this means a minimum resistance of

Ris ,min >

200
[MΩ]
Pole No.
After prolonged storage or lengthy operation, the insulation resistance should first be measured with a low
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voltage (<500 V) to rule out any damage to the winding.

ATTENTION
The short circuit wires have to be removed from the semi conductors after the test!

4.2.15 Drying
If the above-mentioned minimum insulation resistance values are not attained, the cause may be
moisture, contamination or damage to the insulation,
It is necessary to dry the stator winding, if
• external moisture, contamination or damage can be ruled out as the cause of the minimum insulation
resistance value being too low.
• external moisture is observed on the winding surface, irrespective of whether or not the minimum insulation
values are achieved.
• after deposits or dirt have been removed, the minimum insulation resistance values are still not reached.
• incompletely hardened resins or varnishes are assumed to be responsible for low insulation resistance values in
the case of repaired machines
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The simplest method of desiccation is a dry area with 80oC clean warm air and with exhaust. Generator
does not have to be disassembled. Concerning generators with high protection e.g. IP 54, the parts that
secure protection must be disassembled. Time of desiccation depends on the degree of humidity.

The other desiccation methods:

- short-circuit operation at IN with foreign exciter
- warming up by means of direct current

Insulation resistance must be measured during desiccation. At the start it will drop down quickly and then
it will raise again. Desiccation is finished when insulation resistance reaches corresponding value. If insulation
resistance of generator is not improved after longer period of desiccation, then the low value is not caused by
humidity in stator. There must be another defect.
Record to the operational log that the drying has been done.

Only qualified professionals can carry out cable lead to generator and its connection to switching and
protective apparatus. And they have to adhere to valid regulations and standards. Cables must be thoroughly
connected, and can stress connection terminals neither in tension nor in bending.

Connection cables are connected in compliance with connection diagrams that can be found on inner side
of terminal box cover. Terminal bolt must be properly tightened so as not to warm up and loose due to
resistance during operation. Terminal box must be closed after the connection is finished.

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4.3 Electric installation
4.3.1 Making the electrical connections
(cable terminal compartment for stator connection)
The electrical connections inside the machine are made at the factory, taken to the cable terminal
compartment for the stator connection (see text to dimension drawing) and subjected to an HV winding test.
To make the stator connections, open the cable terminal compartment and the marked earthing terminals in
the cable terminal compartment and the conductor clamp. The terminals are designed to receive cable lugs see
(Fig. 15). Connect the supply lead in accordance with the main terminal diagram, pay attention to the right
direction of rotation (see text to dimension drawing). The conductors should make good electrical contact,
which entails the contact surfaces should be free from irregularities the contact surfaces should be metallic-
bright (i.e. treat the surfaces with a clean, mediumfine steel-wire brush, dirt and oxidation should be removed)
the contact surfaces should be greased with acid-free vaseline the connecting elements should be carefully
assembled and tightened with the specified torque (Tab. 5).

The factory recommends making the connections as shown in (Fig. 15)

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01 Incoming cable to stator terminal

02 Cable lug to DIN 46235
03 Terminal in terminal box (ready drilled to receive 16 mm or
20 mm dia bolt)
04 Fixing elements
Hexagonal bolt, DIN EN 24017 (ISO4017), 8.8-A-A3C
Hexagonal nut 6, DIN EN 24032 (ISO4032), 8-A-A3C
Spring washer , DIN 128, spring steel Washer, DIN 125, St-
A3C
05 Conical spring washer, DIN 6796, spring steel Washer,
SN 62501, St-A3C
02 03 01 04 05 03 01 02
Fig. 15 Recommended stator terminal arrangement

The bolts are to be tightened with a torque wrench. The tightening torques for electrically conducting con-
nection bolts are shown in (Tab. 5). Connections are provided in the terminal box for earthing the cable
sheaths (see dimension drawing). The connections and sealing ends should comply with the local regulations.
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Size of connection elements M10 M12 M16 M20

Material St St St St
Strength class 8.8 8.8 8.8 8.8

Tightening torques in Nm 40 70 155 340

Tab. 5 Tightening torques for screwed electrical connections

The cable entry of the cable terminal compartment is closed off by a plate of insulating material (see dimension
drawing).
The holes required for entering the cables must be drilled during installation in accordance with the cable
clamps used.
The cable entry point must be suitably sealed on completion of cable installation.
Before closing the cable terminal compartment, check that the screwed electrical connections have been
made properly the inside of the cable terminal compartment is clean and free from trimmed-off ends of wiring
material the minimum air clearances are adhered to in accordance with the local regulations, taking account of
protruding ends of bolts and conductors unused cable entries are closed and their connecting elements are
securely screwed in.
As an example, (Tab. 6) lists the minimum air clearances laid down in DIN EN 60079-7 (VDE 0170-6).

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Working voltage V Minimum air distance mm
550 < U <= 750 10
750 < U <= 1100 14
5500 < U <= 6600 60
8300 <U <= 11000 100
13 800 140 1)
1) Not contained in DIN
Tab. 6 Minimum air distance
4.3.2 Making the electrical connections
(terminal box for auxiliary circuits)
At the factory, the conductors from supply and monitoring devices are routed inside the machine to a
separate terminal box with line-up terminals (see dimension drawing and associated text). The terminal
assignment is shown on the auxiliary terminal diagram. Consult the dimension drawing text for details of the
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maximum conductor cross-sections that can be connected.

The appropriate types of screwed gland for incoming cables are listed in the dimension drawing. Before
closing the terminal box:
Consult the terminal diagram before connecting the incoming conductors
Check that the inside of the terminal box is clean and free from odds and ends of wiring material
Ensure that unused cable entries are closed and that the plugs are screwed down tight.

4.3.3 Safeguarding
Generator must be well protected by means of regressive protection to prevent dangerous operational
situations and overcurrent defects. Generators must be safeguarded in compliance with nominal current that
is determined in output name plate.

4.4 First start and operation

4.4.1 Installation
Prior to launching a driving machine, the following must be checked:
- Visual inspection of the machine (external, internal state) – according by Tab. 7
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- Generator load must be disconnected

- Insulation resistance must be kept at least to minimal value
- Safety regulations concerning operation of aggregate must be adhered
- Protective wire must be connected
- Before first start of the machine, open the reduction valves to their maximum position.
- When the machine reaches the nominal speed only adjust oil flow according to the dimension
drawing text. After adjusting the oil flow, lock the reduction valves.

Item Points to check Inspection and maintenance work

If you identify any damage or signs of

damage, then initiate measures to
remove the damage or to limit the
Mechanical damage, wear, damage. When required, inform
Visual inspection of the machine paint damage, corrosion, Siemens service, see page (45). In case
(external, internal state) leaks, dirt, foreign bodies, of detection of any moisture, it is
porous seals. necessary to measure according to
chapter 4.2.13 Checking the
insulation resistance of stator
winding and 4.2.15 Drying

Tab. 7 Visual inspection of the machine

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When the check is over the whole aggregate can be launched according to operational instructions
designed for the whole set.
In case that the machine is not put out of operation for more than 3 months, only a visual inspection
(according by Tab. 7) is sufficient before the connection starts.

4.4.2 Change of rotating direction

Change of rotating direction is possible only in generators equipped with a fan that can rotate in both
directions. Change of direction is performed by switching over the terminals k and l of current transformer
(Fig. 20). Change of rotating direction is accompanied with the change of phase sequence on the main
terminals. Rotating direction cannot be changed in generators that have got only one-way fan. The fan must
be exchanged.

4.4.3 Operation
! WARNING If any changes occur that are different from normal operation (higher input, temperature or
vibrations, unusual noise or smells, reaction of control devices etc.), it means that function is damaged.
Maintenance staff must be called immediately to prevent breakdowns that can directly or indirectly jeopardize
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people or that can cause damage to property.

IN CASE OF ANY DOUBTS, IMMEDIATELY DISCONNECT APPROPRIATE DRIVING MECHANISM

WARNING
Oil supply unit
The sleeve bearings must be always lubricated when the machine is under operation.
Oil supply unit must be always switched on before machine operation otherwise can cause bearing or
bearing brass damage.

Generator is able to be excited itself. But the following must be taken into consideration:

- Required terminal voltage in the extent of UN ± 5% or according to technical specification can be set
by external potentiometer after nominal revolutions are reached.
- Generator can be fully loaded after nominal speeds are reached

The following operational data must be checked again:

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- Current, generator cannot be overloaded

- Symmetry of load of individual phases
- Frequency
- Increase of temperature in bearings, cooling of machine and mechanical operation
To prevent resonance, take heed of the following: own electromechanical frequencies of generator
must not be in accordance with mechanical exciting frequencies of driving machine.

4.4.4 Check of operation

The function of generator must be continuously observed during operation so as to avoid a breakdown.
Its course must be recorded in generator operational logbook, especially the changes that are unusual in
the course of normal operation. Any found imperfections must be repaired immediately. Above all,
generator must be clean, must be secured in accordance with the data on output name plate, running
must be centred without vibrations, perfect condition of bearings and good tightening of connection
terminals. During generator operation ventilation openings must not be covered in any way. If a generator
was out of operation for longer period, insulation resistance of winding, condition of lubrication in
bearings, tightening of terminal bolts and mechanical connection with driving machine must be inspected
prior to putting the machine into operation.

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4.4.5 Safety measures at stationary machine ready for start up
Machines standing by ready for start-up require special protection if they are exposed to a harsh environment.
Such a situation can occur during:
• the time between the end of installation and the
• commissioning of the machine,
• pauses between two operating times,
• idle time of standby machines.
The following measures are to be taken so that the machine can remain on standby without any detrimental effects:
• Prevent condensate forming in the machine, e.g. by space heating
• Give the air-water-cooler anti-corrosion treatment (see operating instruction: "Air-to-water cooler")
• Check condensation water
• Start up the machine at regular intervals (such as once a month). Should it not be possible to start up the
machine, the rotor should at least be rotated several times through 180° over the same period.

4.4.6 Intervals of preventive inspections

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4.4.6.1 Preventive inspection I.

Is carried out regularly in the course of common operation of the machine after 500 and 5000 operational
hours from the beginning. The inspection consists of:

a) Inspection of cleanliness of cooling surfaces of machine.

b) Measurement of stator winding insulation resistance.
c) Inspection of bearings operation.
d) Inspection of function of additional equipment.
e) Measurement of rotor winding circuit insulation resistance.(rectifier have to be short-circuited –
all connectors of rectifier have to be connected, measuring voltage is 500V)

Any found imperfections must be repaired prior to putting the machine into operation.

4.4.6.2 Preventive inspection II.

Is carried out regularly after 5000 operational hours from the beginning.
The inspection consists of:

a) Inspection of cleanliness of cooling surfaces of machine.

b) Measurement of stator winding insulation resistance.
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c) Measurement of voltage, current, temperature, bearings and oscillations.

d) Inspection of bearings operation.
e) Inspection of connection to the net and tightening of terminal bolts.
f) Inspection of tightness of terminal box cover.
g) Inspection of function of additional equipment.

Any found imperfections must be repaired prior to putting the machine into operation.

4.4.6.3 Preventive inspection III.

Is carried out regularly after 15000 operational hours from the beginning.
The inspection consists of:

a) Thorough cleaning.
b) Thorough inspection.
c) Reparation of any imperfections.
d) Bearings re-lubrication.
e) Measurement of stator winding insulation resistance.
f) Measurement of rotor winding circuit insulation resistance.( rectifier have to be short-circuited – all
connectors of rectifier have to be connected, measuring voltage is 500V)
g) Tests.
Any found imperfections must be repaired prior to putting the machine into operation.
All inspections must be recorded in the generator operational logbook.

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4.4.7 Putting out of operation
Loading must be disconnected before generator is put out of operation. Next steps should follow
operational instructions prescribed for the whole set.

4.4.8 Operational log

The operational log serves for recording all events that relate to operation, maintenance and revisions of the
generator. Keep the records starting from the storage period before putting the generator into operation.
Record the current number of the operational hours to the "Operational hours" box starting from the first
commissioning.
Record also all events that are related to winding insulating resistance, drying, and record parameter values
(e.g. voltage, current, bearing temperature, vibration, etc.) during both the commissioning and normal
operation.
The operational log is also used to record the results of all inspections and revisions. All machine
modifications, part replacement, faults of generator, accessories, switching and breaking elements including
their replacement are recorded to the operational log. Moreover, emergency events are also recorded (e.g.
overload, short circuit, etc.) even if no generator failure occurred.
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The record in the operational log may refer to another document in which the activity is evidently recorded.
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4.5 Diagnostics of defects

4.5.1 Mechanical causes

Breakdown
Radial vibration

Excessive noise
temperature of

Axial vibration
Scratchy noise

Possible cause Remedy precaution

Bearings are
overheated

generator
Excessive

• Contact of rotor or shaft with

solid parts of machine appears
Find and eliminate cause
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Limited access of air, excessive

• amount of dust in winding,
dust in cooler ducts
Perform check of access of air,
pollution of winding, check cooler

• Polluted or blocked air filter (if

it is equipped)
Filter exchange, if need to clean

Clean cooler with regards to

Cooler function gets worse
• (goes for design with water
cooler)
operational instructions, check
amount of cooling medium, vent
cooler

• Unbalance on rotor
Contact producer and require
balancing

• Unbalance in coupling Rebalancing

• Transfer of vibration from

linked machine
Check of linked machine

Badly fixed generator in

• • foundation or changes in
Level machine, check foundation,
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and tightening of generator

foundation

• • Resonance with foundation Strengthen foundation

• Lack of lubricant in bearing Check amount of lubricant in bearing

• Bearing is overloaded
Check tightening, levelling and
clamping of machine

• Damaged or badly worn out

bearing
Perform exchange

Tab. 8 Mechanical causes

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4.5.2 Electric causes I

Breakdown
UN cannot be set by means

Generator voltage app.0,1

Generator voltage >1,1 UN

cannot be set by means of
of potenciometer VOLT
Generator voltage < UN

UN (remanent voltage)

Outside control device

Current and voltage

with no function
control device

drifting
Possible cause Remedy precaution

• Too high number of speeds Check speeds of drive

•
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Too low number of speeds Check speeds of drive

• Oscillation of number of speeds Check speeds of drive

• • Defect on rotating rectifier

Check diodes, exchange diode
module

• Defective varistor or diodes Exchange varistor or diodes

• Break in circuit Check wires

• Break in regulator feeding

Check wires from auxiliary
winding to regulator

• Defect on fuse F1 Exchange fuse

• Break in exciting circuit

Check wires from regulator to
exciter
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• • • Defective voltage regulator Exchange regulator

New adjustment of

• Stability potentiometer reset

potentiometer, stability according
to operational instructions of
regulator
New adjustment of

• Frequency potentiometer reset

potentiometer, frequency
according to operational
instructions of regulator

• Breakdown in circuit of planned

values, short-circuit in leads
Eliminate short-circuit

• • Breakdown in circuit of planned

values, interruption in leads
Eliminate interruption

During operation of Input bridge or attach external

• potentiometer of planned
values bridge is missing
potentiometer with planned
value

Tab. 9 Electric causes I

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4.5.3 Electric cause II

Breakdown

among individual phases

during parallel operation
Uneven load distribution
Generator voltage < UN

Fluctuation of output
Difference of voltage

Part of winding is
Overheating

overheated
Possible cause Remedy precaution

• Overload Reduce load

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• Break of outer wires Check outer wires

Measure winding and insulation

• Short-circuit of stator
winding
resistance, consult producer and
repair

• Overload Reduce load

• Uneven load Adjust load

Measure winding and insulation

• Short-circuit of stator
winding
resistance, consult producer and
repair

• Fluctuation of turning
moment
Check driving machine

In generator equipped with statics

• Potentiometer of statics is
reset
module-set potentiometer of
statics according to operational
instructions
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Break or short-circuit of lead

• from statics current
transformer T to statics
Eliminate short-circuit, in case of a
break check current transformer

Tab. 10 Electric causes II

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5 Maintenance

5.1 Safety recommendation

! WARNING Pay heed to strict adhering to “General safety information” in paragraph 1.2 of these
instructions. Unconditionally pay heed to necessary professional knowledge that must be acquired while
operating in heavy-current machinery.

Before any work on machines is started, make sure that machine or unit is disconnected in accordance to
regulations. This applies especially for opening of protective covers.
Pay heed not only to main current circuits but also to possible supplementary auxiliary current circuits. This
especially applies to heater in the course of stoppage of machine.

5.2 Five safety rules

The usual "five safety rules", according to DIN VDE 0105-100, for example, are:
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- disconnection
- securing that prevents new connection
- make sure that machine is disconnected
- earthing and short-circuit connection (for voltage above 1000 V)
- block or cover (close) neighbouring active parts.

NOTICE
Cross-section drawings and or detailed drawings that are a part of instructions, usually contain useful
information on technical construction of normal machines and constructional groups. This information
can be appreciated by experts and should be taken into consideration in a certain way.

ATTENTION
Special designs and constructional variants can differ from normal projections as far as technical details
are concerned. We are here to solve any potential uncertainty, please, contact us and provide us with type
and production number of a machine. Other possibility is to contact directly SIEMENS service centre and
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have maintenance works performed by the centre.

WARNING
Any works that are performed on generator must be carried out on disconnected machine, apart from
relubrication of bearings. In that particular case it is necessary to adhere to safety instructions. If the works
are performed on the parts of machine or accessories under current , make sure that generator is always
separated from the network. At the same time check if these parts are not under voltage. Protective wire
must always be connected.

5.3 Inspection of insulation condition

Condition of generator insulation must be inspected during every maintenance and prior to putting into
operation in case of longer period of a shut down.

5.4 Cleaning
Generator and its accessories must be kept in clean condition. Cleaning must be carried out in dependence
on operational requirements.
The best way of cleaning is to use clean and dry pressed air (most 200 kpa). Collecting dust decreases
cooling capacity and increases raise of temperature of machine.

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If generator is fitted with a filter in the inlet spot of cooling air, then it must be cleaned regularly. Cleaning
intervals depend on conditions of ambient surrounding in which generator operates. Degree of contamination
can be assessed in dependence on increase of temperature of stator winding which is normally equipped with
resistance thermometer (concerning designs with a filter). Filter is disassembled and blown with pressed air.

Keep a record of cleaning in the operational log.

WARNING
Pay heed to suitable exhaust and personal protective aids (protective goggles, filter, respirator etc.) in the
course of pressure cleaning!
When chemical cleaners are used, please, adhere to warning and safety recommendations that are stated
in appropriate list of safety data (see General safety information 1.2). Chemical cleaners must be
applicable for machine parts, especially parts made of plastics.

5.5 Bearing maintenance

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5.5.1 Antifriction bearings

Generator antifriction bearings are filled with lubricating grease and ready for operation. Generators are
provided with bearings including relubrication equipment and grease amount regulator.
Bearing type together with lubricant used are given complementary rating plate at each lubrication point.
Relubrication intervals, if any, are given in Annex.
Grease amount must be regularly checked in antifriction bearings and exchange, if necessary. New grease is
to be filled during the preventive inspection III., no later than after 3 years. During maintenance the bearing
part must be cleaned and new grease filled.

In case the bearings are equipped with waste for used grease, after each regreasing of antifriction bearings
(according to lubrication plan) take off the cover of the waste and used grease také out. As the used grease is
took out return the cover.

Keep a record of additional lubrication in the operational log.

5.5.2 Sliding bearings

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Maintenance of sliding bearings is specified in manufacturer’s Manual which is enclosed.

Take care of the following: - a regular oil exchange at specified intervals,
- checks of screwed joints,
- checks of temperature sensors.

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5.6 Troubleshooting components on rectifier supporting wheel
If a fault arises, it is advisable to notify the factory because it is the only source of any additional spare and
replacement parts that may be required. In special cases it is best to request delegation of Siemens personnel.
To perform work on the rectifier supporting wheel (Fig. 16), it is necessary to open the service covers
provided at the NDE end of the housing top section.

5.7 Rotating rectifier – inner excitation system

The rotating rectifier is composed of silicon diodes connected to 3-phase full-wave rectifier circuit.
Commutation surges are absorbed by varistors which are in parallel with diodes.

1. Hub
2. Heat sink
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3. Spherical cap, diode

4. Varistor disc
5. Collector ring +
6. Collector ring –
7. Fixing screw M16 for heat sing
8. Insulating washer
9. Connector bar +
10. Connector bar –
11. Fixing screw M6 for spherical cap
12. Fixing screw M12 for collector rings
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Fig. 16 Assembly kit for rectifier wheel with diodes (illustrative only)

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5.7.1 Changing the rectifier diodes

The rectifier diodes (disk-type diodes) are located inside spherical caps which are arranged in pairs on a heat
sink. The heat sinks are insulated and fastened on the hub.
If diodes have to be replaced, the replacement diodes should only be unpacked shortly before installation,
and once unpacked should be installed immediately. Be careful to avoid hard impacts that might damage the
replacement diodes.

Proceed as follows to replace the diodes:

1. Disassemble the front cover of the exciter housing
2. Unscrew connector bars and fixing screws of the spherical cap.
3. Take the cap carefully off and replace diodes.
4. Coat the contact surfaces of the new diodes with contact oil.
5. Insert diode on the heat sink. Keep the polarity in accordance with marks on the heat sink and
connector bars.
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6. Carefully mount the spherical cap and clamping covers in the reverse order described above.

4 3 5

1
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Fig. 17 Diodes assembly (seen from collector rings side)

1. Heat sink
2. Spherical cap
3. Diode
4. Fixing screw M6 for spherical cap
5. Fixing screw M16 for heat sing
6. Insulating washer

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5.7.2 Changing the varistors

The varistor discs designed to protect the rectifier diodes are installed axially between the bus rings of the
rectifier supporting wheel.

Proceed as follows to replace the varistor:

1. Remove the corresponding fastening screw and pull out the insulating sleeve.
2. The varistor disc can then be removed between the collector rings.
3. When replacing the varistor disc, be sure to replace the spacers as well.
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Fig. 18 Varistor assembly

1. Hub
2. Collector ring +
3. Collector ring –
4. Varistor disc
5. Spacer
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6. Fixing screw M16 for collector rings

7. Insulating sleeve
8. Insulating washer

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6 Disassembly and regressive assembly

6.1 Dismantling and reassembling machines 1D

This work must always take place in a clean, dust free and dry environment.
Power cables must be disconnected. CAUTION! – this work may be carried out by a qualified worker only.
Auxiliary circuits of regulation, checking and protective circuits are connected in an LV terminal box and are
disconnected in case of a total generator dismantling only. If rectifier is to be replaced, only its cooler (01) is
removed. Bearings are replaced after removing bearing caps bolts (03) and bolts tightening bearing cap (02).
After the shaft is picked up the bearing cap can be taken out on rear side (04) and after removing rectifier
carrier (05) also bearing cap on machine front side (06) can be removed.
For checking rotor and stator windings it is necessary to dismantle the machine, i.e. to disconnect all
cables in LV terminal box and power cables, to remove bolts (07) and cooler extension (08), to loosen bolts
(09) and remove shields. Checks of power cables connection can be carried out after removing the extension
guard opposite cable outlets (10).
For oil checking and exchange in sliding bearings (11) – see Operator’s Instructions.
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Generator reassembly is carried out in reverse sequence of operations. In order not to apply any force,
appropriate tools must be used for reassembly.
If the generator differs from the basic model, e.g. by an arrangement of feet with two bearings,
dismantling and reassembling may be different in some way. In case of variants equipped with air filter, air
water cooler, other guard, special shape or mechanical design always complementary instructions are
enclosed.
Keep a record of dismantling in the operational log.
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Fig. 19 Dismantling and reassembling

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7 Regulation

7.1 General description, control principle

The purpose of the control system is to maintain a constant terminal voltage on the main machine
irrespective of the load and the power factor. Voltage regulator measures generator voltage and compares it
with the adjusted value. Exciter winding obtains the required direct current via voltage regulator actuator
which is fed by an auxiliary winding inside the main machine stator. The three-phase winding of the exciter
feeds the main machine rotor via rotating rectifiers. A varistor restricts voltage peaks to permissible values.
A specific model of the voltage regulator used . its connection and description are given in the Annex to
Operating Instructions. On request the generator can be additionally equipped with power factor cos ϕ ,
whose details are also given in the Annex.
Compact voltage regulators are moisture- and vibration-resistant. Generator self-excitation is provided by a
sufficiently high remanence in exciter stator.
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L1 L2 L3 RH rotation

L2 L1 L3 LH ROTATION (SWITCH OVER TERMINALS TO A1 OF CURRENT TRANSFORMER)

A1 regulator
F1 fuse
G1 main machine
G2 exciter
A1
H auxiliary winding
R1 external potentiometer
T1 current transformer
U varistor
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V2 rectifier

Fig. 20 Regulation

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7.2 Range of voltage regulation
Terminal voltage can be adjusted in the range of ±5,0% of nominal voltage by means of potentiometer that is
situated on regulator. There is an option of supplying external potentiometer designed for remote control.
Optionally it can be supplied with motor control.

7.3 Regulation accuracy

Static accuracy of regulation is ±1% in the range from running without load up to full load as well as during
constant output and change of revolutions of up to ±5,0%.
Other information about regulation accuracy on demand.

7.4 Dynamic states of voltage

Temporary drop of voltage that occurs during connection of full load with power factor cos ϕ makes normally
up to 20%. This value depends on generator size. Time of reregulation makes about 1,5 - 2 s and depends on
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the size of regulator.

7.5 Parallel operation

Synchronous generators 1D are suitable for parallel operation with another generator and network. In
the course of parallel operation, distribution of active load is determined by driving machines. To secure
uniform distribution of active load, regulators of revolutions of parallely working driving machines must be
adjusted at the same characteristics. They can even be equipped with electronic load regulator.

Concerning parallel operation, generators are equipped with static regulator to secure good distribution
of reactive load. Inclination (gradient) of reactive current characteristics can be changed by means of
adjusting of resistance in static regulator.
Statics is set by producer to a value of about 6% - possible range of adjustment is 10%. This adjustment
enables voltage swing up to ±2,5% in parallel operation of network without exceeding maximum reactive
generator current. If higher line voltage swing appears, it is necessary either to increase statics or and to
regulate terminal voltage by means of power factor regulator.
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8 Neutral wire

8.1 Generally
In the course of parallel operation of generators amongst themselves or with the line, differential currents can
appear as the result of distribution harmonic oscillation of 3rd order. Differential currents are added to phase
currents and can result in inadmissible raise of temperature of generators. Neutral current must not exceed
50% of nominal current. If currents are higher, it is necessary to adopt suitable remedies concerning limitation
e.g. current limiting choke.

9 Generator disposal after lifetime expiration

After expiration of the generator lifetime it is user’s responsibility to dispose it ecologically. It is recommended
to use the service of an authorized company.
It is necessary to disassemble the generator and separate individual materials.
The machine disposal may produce environment-demanding waste, such as grease or insulation material
remaining.
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For machine ecological disposal including unexpended parts of the machine (e.g. packing materials - plastic,
wood, metal) obey the legal regulations in force in particular country.
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10 Contacts

Contacts for further information

Details regarding the design of this electrical machine and the permissible operating conditions are described
in this operating instruction.
If you wish to order spare parts, please contact Customer Service or other contacts below.
If you have any technical queries or you require additional information, please contact the Siemens Electric
Machines or Customer Service - Manufacturer. Please have the machine data and especially machine serial
number ready.
You can find machine data on the rating plate of the machine.

Address
Drásov 126
664 24 Drásov
Czech Republic
Proprietary data, company confidential. All rights reserved.

Tel: 420 549 426 103

Fax.: 420 541 231 028
Web: http://www.siemens.cz/semd

10.1 Customer Service – Manufacturer

Tel: 420 549 426 440
Fax: 420 549 426 450
E-Mail: [email protected]
Internet:
http://www.siemens.cz/semd
https://www.cee.siemens.com/web/cz/en/corporte/portal/Siemens/industry/semd/Pages/Service.aspx

10.2 Service Coordination Center and Industry Hotline – Worldwide

Intranet: http://portal.automation.siemens.com/ld_servicemeldung
E-Mail: [email protected]
Fax: 49 911 433 61 6666
Global Industry Hotline
Germany: 49 (0)911 895 7222
Als Betriebsgeheimnis anvertraut. Alle Rechte vorbehalten.

America: 1 423 262 2522

Asia: 86 1064 757575

10.2.1 I CS LS LD - USA territory

Technical support
1-800-333-7421 (inside USA)
1-423-262-5710 (Outside USA)
Spare Parts and Repair
1-800-241-4453 (inside USA)
1-423-262-5710 (Outside USA)
http://support.automation.siemens.com/us

Operating manual, 1DB revision A 2/2014, Project: CMHIMT6024, Type: 1DB 1036-8AY05-Z page 45/45
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 OPERATION AND MAINTENANCE MANUAL
OF LUBRICATING DISTRIBUTION

Contract number 1401069

Project title CMHIMT

Date 22.1. 2014

Date: Elaborated by:

22.1. 2014 Marek Piše
Introduction

This accompanying documentation is part of delivered lubricating distribution – of hydraulic

aggregator, this documentation contains relevant technical date and instructions important for
correct manipulation, installation, commissioning, operation and maintenance delivered
installation.
Pay attention to the contents of this file before putting installation into operation.
This manual will be useful tool for you during operation and using of delivered lubricating
distribution.

Manufacturer contact information:

Marek Piše
Tererova 3
Brno – Královo Pole
Czech Republic

IČO: 633 76 989

DIČ: CZ 75 07 12 3866

Service:
Marek Piše , mobile: +420 776 025 134
[email protected]
 Operating instructions of oil economy of bearing lubrication

Introduction:

The hydraulic aggregate is used for bearing lubrication, cooling of lubricating oil. It is
necessary that the operation of electrical machines was given due care as an important part of
electrical machine. This operating instructions and operating manual is part of the operational
documentation of electrical equipment.

Guarantee:

The guarantee is tied to compliance of the technical instructions and of the following
technical conditions. The breach of these regulations may be grounds for rejection of the
pretension that results from guarantee. In the complaint, and ordering of spare parts is
necessary to include the serial number of the engine, generator, or other label information.

The hydraulic aggregate can be removed by the operator only with the approval of the
manufacturer of electrical machine, otherwise guarantee claims expire. The operator is
obliged to properly keep the operating book of engine for the recognition of the
guarantees.
During the guarantee period you must not be performed external or internal
intervention into the hydraulic unit.

Technical description:

The hydraulic aggregate is equipped by gear pump, which constitutes a source of pressure.
Gear pump is connected with an electric motor by the help of cross conjuction that transmits
torque. In addition, it consists of coolers oil - water, flow meter, check valve and necessary
piping.

The hydraulic aggregate is not designed for operation in explosive environments.

description of the fiction:

AS side – bearing

When the gear pump is running the oil is sucked from the bearing box and pushed out into
the oil cooler - water. The output of oil from the water cooler is routed through a flowmeter
back into the bearing.
Cooling water should be connected to the input and output of coolers.

Transport and storage:

The hydraulic aggregate is part of the electric machine. Is necessary to ensure that will not
damage the part of the bearing oil lubrication during any handling with the machine. All parts
must be protected during handled and transport.
Operations and operating personnel:

The initial inspection must be carried out before the first run of machine so that the
correctness of connection and condition of the hydraulic unit was verified for safety.

Closet bearing is filled by oil to mid of relevant oil emblem. Typ of oil is prescribed in the
documentation of electrical machine.

Before the first run, it is necessary to examine the tightness of all joints so that the pump the
hydraulic unit will turn on. After 5 minutes running of the pump, all joints should be
checked, whether oil is leaking. If oil leaks from the joint, is necessary to repair this joint,
during this operation the machine has to be turned off.

After this test ,the bearing is added by oil back to mid of relevant oil emblem. This applied
even when changing the oil in the bearing.

Any leaks of joints of pipeline are removed by help of adequately tightening union nuts.

Maintenance:

Maintenance consists of checking and possible replacement of sealing elements, adding the
relevant oil to the circuit. Checking the oil level must be performed periodically before each
launch of machine.

Service book:

It is used to record essential events that relate to operation and maintenance of the oil
economy. It starts with the records at the time of storage before to commissioning.

Technical data of components:

item title manufacturer Technical informations

1 Gear pump Marzocchi 1P-D-5 / fa Marzocchi

Pompe

2 Return valve Eaton P-RV-12L

3 Flange HL 2 Marzocchi Typ: HL 2

Joint HE 2 Pompe Typ: HE 2

4 Water cooler Emmegi MG 81-310 – 2 Pass

DKM / A – 1/8, G ½“ MS
5 Flowmeter DKM / A Meister Brass, changeover contact,

Flanged ekectric motor

6 Electric motor Siemens Typ: 1LA7070 – 4AB91
-Z-E51- L1Y
Faults and causes:

Fall in flow of oil or no flow of oil into the bearing:

- Faulty electric motor of pump

- Faulty pump
- quantities of oil in the the body of bearing
- Suction bearings – leak
- Flow sensor faulty

Increase in oil temperature:

- High temperature cooling inlet water

- Low or no flow of cooling water
- defect of bearing

Liquidation of oil economy:

Used oil and used components of oil economy are stored to avoid uncontrolled release, then
they are forwarded to a company that deals with the ecological disposal of hazardous waste.
 Operating book of the aggregation

Date Notes Name Signature

 s

Typical notation for

Synchronous generators 1 D B 06 24 - 4 A V 03 - Z
Synchronous machine D Number of pole pairs

Rotor type Stator voltage and frequency

cylindrical rotor B B 50/ <6.3
salient pole rotor C C 50/ 6.3
cylindrical rotor, steem and gas turbine U D 50/ 6.3 - 11.0
Salient pole rotor, water turbine H E 50/ 11.0
Salient pole rotor, piston machine K F 50/ >11.0
H 60/ <4.16
Diameter of stator core (coded) J 60/ 4.16
K 60/ 4.16 - 6.6
Standard frame size just For 1DB, 1DC L 60/ 6.6
400 mm frame size 03 M 60/ 6.6 - 13.8
450 mm frame size 04 N 60/ 13.8
500 mm frame size 05 P 60/ >13.8
560 mm frame size 06 V 50/≤0.5
630 mm frame size 08 W 50/≤1.0
710 mm frame size 10 X 60/≤0.5
800 mm frame size 12 Y 60/≤1.0

Length of stator core (coded) Mounting and Ex-protection

A IM B... no Ex-protection
Degree of protection B IM B... E(Ex) p
IP 00 0 C IM B... E(Ex) n, E(Ex) e
IP 11 1 D IM 7… no Ex protection
IP 20 2 E IM 7… Ex protection
IP 21 3 F IM B… Eex n, e
IP 23 4
IP W24 5
IP 44/54/55/56 Tube 6
IP 44/54/55/56 CACA 7
IP 44/54/55/56 CACW 8

Revision A 27.05.10 Siemens Electric Machines s.r.o.

 s

Typical notation for

Asynchronous motors 1 T V 12 44 - 8 A E 02 - Z

Asynchronous machine T Number of pole pairs

Rotor type Stator voltage and frequency

squirrel cage rotor C B 50/ <6.0
squirrel cage rotor, A-modyn V C 50/ 6.0
D 50/ 6.0<U<10.0
Diameter of stator core (coded) E 50/ 10.0
F 50/ >10.0
H 60/ <4.0
Length of stator core (coded) J 60/ 4.0
K 60/ 4.0<U<6.6
L 60/ 6.6
Degree of protection M 60/ 6.6<U<13.2
IP 00 0 N 60/ 13.2
IP 11 1 P 60/ >13.2
IP 20 2
IP 21 3
IP 23 4 Mounting and Ex-protection
IP W24 5 A IM B... no Ex-protection
IP 44/54/55/56 Tube 6 B IM B... E(Ex) p
IP 44/54/55/56 CACA 7 C IM B... E(Ex) n, E(Ex) e
IP 44/54/55/56 CACW 8 D IM 7… no Ex protection
E IM 7… Ex protection
F IM B… Eex n, e

Revision A 27.05.10 Siemens Electric Machines s.r.o.

 s

Typical notation for

Synchronous motors 1 D V 12 44 - 8 A E 03 - Z

Synchronous machine D Number of pole pairs

Rotor type Stator voltage and frequency

salient pole rotor, A-modyn V B 50/ <6.0
C 50/ 6.0
D 50/ 6.0<U<10.0
Diameter of stator core (coded) E 50/ 10.0
F 50/ >10.0
H 60/ <4.0
Length of stator core (coded) J 60/ 4.0
K 60/ 4.0<U<6.6
L 60/ 6.6
Degree of protection M 60/ 6.6<U<13.2
IP 00 0 N 60/ 13.2
IP 11 1 P 60/ >13.2
IP 20 2
IP 21 3
IP 23 4 Mounting and Ex-protection
IP W24 5 A IM B... no Ex-protection
IP 44/54/55/56 Tube 6 B IM B... E(Ex) p
IP 44/54/55/56 CACA 7 C IM B... E(Ex) n, E(Ex) e
IP 44/54/55/56 CACW 8 D IM 7… no Ex protection
E IM 7… Ex protection
F IM B… Eex n, e

Revision A 27.05.10 Siemens Electric Machines s.r.o.

 Three-Phase Synchronous Generator with Laminated Cylindrical Rotor

Nominal data Type 1DB1036-8AY05-Z

Output SN 3168 kVA Standard IEC 60034
Voltage UN 690 VY Marine classification DNV
Frequency fN 60 Hz Ex-Protection -
Power factor p.f. 0,9 Ex-Standard -
Current IN 2651 A Cooling system IC81W
Speed nN 720 min-1 Ambient temperature 45 °C
Torque MN 42,0 kNm Cooling water temperature 38 °C
Winding pitch 2/3 no Installation altitude 1000 m
Excitation brushless with AVR and auxiliary winding Insulation class 155 (F)
Mounting IM 1101 Stator Winding Temperature <= 145 °C (R)

Enclosure IP 44 Field Winding Temperature <= 150 °C (R)

Reactances and time constants Zn 0,150

unsat. sat. unsat. sat.
xd 267,0 222 % xq 242,0 200 % Td0' 1,373 s
xd' 29,9 19,5 % xq' % Td' 0,153 s
xd" 20,3 13,5 % xq" 23,4 15,5 % Td" 0,005 s
x2 21,8 14,5 % x0 11,6 11,6 % Ta 0,050 s

Efficiencies
S/Sn 25 50 75 100 110 %
Power factor 0,90 95,6 95,9 96,0 96,0 %
Power factor 1,00 96,1 96,5 96,5 96,5 %

Short circuit data

Ik" 19,64 kA Initial short circuit current (3 ~)
IS 49,87 kA Max. peak current (3 ~)
Ik 7,95 kA Sustained short circuit current
kc 0,45 Short circuit ratio
Mk2 404,6 kNm Initial short circuit torque (2~)

Other data
AVR type DECS 100 Axial force at nominal conditions* 1,6 kN
Losses to be dissipated 120 kW Excentric force CM (n=0) 60 kN·mm-1

* In case of non-locating bearings this will have effect on the shaft end.

Remarks
Overload: 10% for 1 h every 6 h.

Change Notice Date Name Project No. Project Code

- issued 07.08.2013 Cibulka Electrical Data Sheet 3208015, 3208016 CMHIMT6024
Job No. Document No.

1401069 D-703491
Customer Page
1 of 1
 s
Proprietary data, company confidential.. All rights reserved.

Operational logbook

Operational logbook of generator

Type of generator: Voltage: Power: Production number:

Entrepreneur: Plant: Workplace of generator: Sheet

1
Count of
Date operation Records: Name Signature
Als Betriebsgeheimnis anver traut. Alle Rechte vorbehalten.

hours

4-1- Logbook of generator.doc Page 1

 s
Proprietary data, company confidential.. All rights reserved.

Type of generator: Voltage: Power: Production number:

Entrepreneur: Plant: Workplace of generator: Sheet

2
Count of
Date operation Records: Name Signature
hours
Als Betriebsgeheimnis anver traut. Alle Rechte vorbehalten.

4-1- Logbook of generator.doc Page 2

 s
Proprietary data, company confidential.. All rights reserved.

Type of generator: Voltage: Power: Production number:

Entrepreneur: Plant: Workplace of generator: Sheet

3
Count of
Date operation Records: Name Signature
hours
Als Betriebsgeheimnis anver traut. Alle Rechte vorbehalten.

4-1- Logbook of generator.doc Page 3

 s
Proprietary data, company confidential.. All rights reserved.

Type of generator: Voltage: Power: Production number:

Entrepreneur: Plant: Workplace of generator: Sheet

4
Count of
Date operation Records: Name Signature
hours
Als Betriebsgeheimnis anver traut. Alle Rechte vorbehalten.

4-1- Logbook of generator.doc Page 4

 s
Proprietary data, company confidential.. All rights reserved.

Type of generator: Voltage: Power: Production number:

Entrepreneur: Plant: Workplace of generator: Sheet

5
Count of
Date operation Records: Name Signature
hours
Als Betriebsgeheimnis anver traut. Alle Rechte vorbehalten.

4-1- Logbook of generator.doc Page 5

 INSTRUCTION MANUAL
FOR
DIGITAL EXCITATION CONTROL SYSTEM
DECS-100

Publication: 9287500991
Revision: L 05/12
 INTRODUCTION
This instruction manual provides information about the operation and installation of the DECS-100 Digital
Excitation Control System. To accomplish this, the following information is provided:

 General Information and Specifications

 Controls and Indicators
 Functional Description
 Installation
 Maintenance and Troubleshooting

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

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

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

9287500991 Rev L DECS-100 Introduction i

 First Printing: March 2001

Printed in USA

© 2012 Basler Electric, Highland Illinois 62249 USA

All Rights Reserved

May 2012

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

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

For terms of service relating to this product and software, see the Commercial Terms of Products and
Services document available at www.basler.com/terms.

BASLER ELECTRIC
12570 STATE ROUTE 143
HIGHLAND IL 62249-1074 USA
http://www.basler.com, [email protected]
PHONE +1 618.654.2341 FAX +1 618.654.2351
ii DECS-100 Introduction 9287500991 Rev L
 REVISION HISTORY
The following information provides a historical summary of the changes made to the DECS-100 hardware,
firmware, and software. The corresponding revisions made to this instruction manual (9287500991) are
also summarized. Revisions are listed in chronological order.

Hardware
Version and Date Change
E, 01/01  Initial release
F, 05/01  Deepened potting shell
G, 10/01  Began supplying mounting screws
H, 02/02  SIL-PADS were added between power components and the heat sinks
 Added manufacturing origin to the rear label
J, 07/02  Revised EEPROM
K, 02/03  Replaced transistor Q8B1 with an improved part
L, 03/03  Incremental improvements to firmware and BESTCOMS
M, 01/04  Improved flash memory retention
N, 05/05  Redesigned current transformer
 Added front panel Underexcitation Limiting indicator
 Enhanced EMI/RFI immunity
O  Version letter O not used
P, 08/06  Updated CD-ROM supplied with unit to include English and French
language instruction manuals
Q  Version letter Q not used
R, 04/07  Resolved UEL issue with firmware modification
S, 05/07  Provided German language manual on CD-ROM supplied with DECS-100
T, 07/07  Released firmware version 2.13.XX
U, 01/08  Improved power amplifier circuitry with more robust components
V, 03/08  Added Setpoint Auto Save feature
W, 03/09  Released BESTCOMS version 1.08.XX.
X, 02/10  Added enhancement for production testing.

Firmware
Version and Date Change
1.09.XX, 01/01  Initial release
1.11.XX, 07/01  Enabled the protection function during the first 5 seconds of operation
 Modified the OEL setpoint scale factor to be compatible with BESTCOMS
version 1.03.XX
 Added the scale factor for per-unit gain
 Established minimum voltage regulation at 30% of nominal sensing voltage
1.12.XX, 03/02  Added register to detect CT type
2.13.XX, 07/07  Added underexcitation limiting
 Added takeover-style excitation limiting
 Added bus voltage matching provisions
2.14.XX, 03/08  Added Setpoint Auto Save setting

BESTCOMS for
Windows® OS
Version and Date Change
1.02.XX, 02/01  Initial Release
1.03.XX, 08/01  Changed OEL scale from 100 to 1,000 to match the change in firmware
version 1.11.01
 Changed OEL default setting from 1 to 15
 Changed the default for all protection functions to enabled
 Add support for French regional settings
9287500991 Rev L DECS-100 Introduction iii
 BESTCOMS for
Windows® OS
Version and Date Change
1.04.XX, 04/02  Made BESTCOMS compatible with older firmware versions
 Added support for all regional settings
 Enabled reading of secondary CT value for units with firmware version
1.12.01 and higher
 Simplified the Analysis screen
 Added feature to calculate and send voltage matching reference for
different generator and bus PT ratios
 Changed minimum Ki setpoint from 0 to 0.01
1.05.XX, 05/05  Added underexcitation limiting capability
 Added ability to select either summing point or takeover style OEL
 Added provisions for bus voltage matching
1.06.XX, 11/07  Added compatibility with Microsoft® Vista to BESTCOMS
1.07.XX, 03/08  Added Setpoint Auto Save setting.
1.08.XX, 03/09  Improved communications with DECS-100.
1.09.XX, 01/11  Added Windows® 7 compatibility and improved field overvoltage
shutdown.

BESTCOMS for
Palm® OS
Version and Date Change
1.01.XX, 01/01  Initial Release
1.02.XX, 08/01  Added a Check for New Version button to the Contact Basler screen
 Added a date/time stamp to the “Save to File” names
 Added version checking
1.03.XX, 04/02  Added password protection
 Improved version checking function
NOTE  BESTCOMS for Palm OS is compatible only with firmware versions
1.12.XX and earlier

Manual
Revision and Date Change
—, 03/01  Initial release
A, 03/01  In Section 5, BESTCOMS Software for the Windows® Operating System
and Section 6, BESTCOMS Software for the Palm OS® Platform, Step 2 of
Installing BESTCOMS was revised to reflect the addition of an auto-start
utility for the DECS-100 CD-ROM
B, 08/01  Added Embedded Software subsection to Section 5, BESTCOMS Software
for the Windows® Operating System
 Corrected various minor errors throughout manual
C, 05/02  Revised the torque specification for the mounting screws supplied with unit
 In Section 5, BESTCOMS Software for the Windows® Operating System
and Section 6, BESTCOMS Software for the Palm® OS Platform, text and
illustrations were revised to accommodate software enhancements
D, 01/03  Revised Voltage Matching Time Adjustment Range from 0 to 300 seconds
to 1 to 300 seconds throughout manual
 Corrected figure number references in Sections 5 and 6
E, 03/04  Added Operating Power Considerations During DECS-100 Programming to
Section 4, Installation, Preliminary Setup
 Added caution box regarding application of operating power during DECS-
100 programming to Section 5, BESTCOMS for Windows® OS and
Section 6, BESTCOMS for Palm OS®
 Corrected CT ratio setting range stated in Section 5

iv DECS-100 Introduction 9287500991 Rev L

 Manual
Revision and Date Change
F, 05/05  Added material covering added UEL capability
 Revised all drawings to show new front panel with UEL indicator
 Updated all illustrations of rear panel to show revised CT
 Added discussion of summing point and takeover style OEL limiting
 Revised voltage matching description to cover Maintain and Revert modes
 Corrected the hole drilling diameter shown in Figure 4-2
 Added illustration/description for using the ICRM-7 with the DECS-100
 Removed Section 6, BESTCOMS Software for the Palm® OS Platform and
moved Maintenance and Troubleshooting to Section 6
 Added troubleshooting procedure for a UEL annunciation
G, 03/07  Corrected illustration and descriptions of BESTCOMS Metering, Operation
and Alarms screen, Operation tab
 Removed expired patent information
H, 05/08  Added DNV compliance statement to manual specifications
 Added description of BESTCOMS Setpoint Auto Save feature
J, 10/08  Revised the setting ranges of control gain settings OEL KI, OEL Kg,
UEL KI, and UEL Kg from 0–1,000 to 0–300 to reflect changes made in
BESTCOMS version 1.07.01.
K, 05/11  Revised Introduction to reflect new epoxy-potted package.
 Removed “(optional feature)” from note 5 of Figures 4-7 to 4-10, due to the
setpoint option now being standard.
 Added storage / electrolytic capacitors procedure to Section 6.
 Corrected various minor errors throughout manual
L, 05/12  Section 1: Added maritime agency recognition.
 Section 4: Added maritime agency conditions of acceptability.
 Section 5: Added caution box regarding PID calculations.

9287500991 Rev L DECS-100 Introduction v

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vi DECS-100 Introduction 9287500991 Rev L

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

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

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

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

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

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

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

9287500991 Rev L DECS-100 Introduction vii

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viii DECS-100 Introduction 9287500991 Rev L

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

Figures
Figure 1-1. DECS-100 Style Chart ............................................................................................................ 1-1
Figure 1-2. Typical V/Hz Curves................................................................................................................ 1-4

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ii DECS-100 General Information 9287500991 Rev L

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

FEATURES
DECS-100 units have the following features and capabilities:
 Four control modes: automatic voltage regulation (AVR), manual or field current regulation (FCR),
power factor (PF) regulation, and reactive power (var) regulation.
 Programmable stability settings.
 Soft start and voltage buildup control with an adjustable ramp in AVR control mode.
 Overexcitation limiting (OEL) and underexcitation limiting (UEL) in AVR, Var, and PF control modes.
 Underfrequency (volts/hertz) regulation.
 Three-phase or single-phase generator voltage (rms) sensing/regulation in AVR mode.
 Single-phase bus voltage (rms) sensing.
 Single-phase generator current sensing for metering and regulation purposes.
 Field current and field voltage sensing.
 One analog input for proportional remote control of the setpoint.
 Five contact sensing inputs for system interface.
 One common output relay for alarm indication and trip functions.
 Three protection functions: field overvoltage, generator overvoltage, and loss of sensing.
 Generator paralleling with reactive droop compensation and reactive differential compensation.
 Rear RS-232 communication port for personal computer communication using BESTCOMS
Windows® based software for fast, user-friendly, setup and control.

MODEL AND STYLE NUMBER

The model number, together with the style number, describe the options included in a specific device, and
appear on a label affixed to the rear panel. Upon receipt of a DECS-100, be sure to check the style
number against the requisition and the packing list to ensure that they agree.

Style Number
DECS-100 electrical characteristics and operational features are defined by a combination of letters and
numbers that make up the style number. The DECS-100 style number chart is shown in Figure 1-1.

Figure 1-1. DECS-100 Style Chart

9287500991 Rev L DECS-100 General Information 1-1
Style Number Example
For example, a DECS-100 with a style number of A15 would have the following characteristics and
operating features.
A ------- No var or power factor control
1 -------- Voltage matching
5 -------- 5 ampere current sensing

SPECIFICATIONS
DECS-100 specifications and qualifications are listed in the following paragraphs.

Operating Power
Refer to Section 4, Installation for special requirements concerning the application of operating power
during DECS-100 programming and the application of station power.
Voltage: 88 to 250 Vac, single-phase or three-phase (L-L)
Frequency: 50 to 400 Hz
Burden: 650 VA
Voltage Buildup: 6 Vac
Terminals: 3, 4, 5

Generator Voltage Sensing

Type: 1-Phase/3-Phase, 4 ranges
Burden: <1 VA per phase
Terminals: E1, E2, E3
50 Hertz Sensing
Range 1: 100 Vac (85 to 132 Vac)
Range 2: 200 Vac (190 to 220 Vac)
Range 3: 400 Vac (380 to 440 Vac)
Range 4: N/A
60 Hertz Sensing
Range 1: 120 Vac (85 to 132 Vac)
Range 2: 240 Vac (170 to 264 Vac)
Range 3: 480 Vac (340 to 528 Vac)
Range 4: 600 Vac (540 to 660 Vac)

Generator Current Sensing

Type: 1-phase (B-phase), 50/60 Hz
Style XX1: 1 Aac maximum continuous
Style XX5: 5 Aac maximum continuous
Burden: <0.1 VA
Terminals: CT1, CT2

Bus Voltage Sensing (Optional)

Type: 1-phase, 4 ranges
Burden: <1 VA per phase
Terminals: B1, B3
50 Hertz Sensing
Range 1: 100 Vac (85 to 132 Vac)
Range 2: 200 Vac (190 to 220 Vac)
Range 3: 400 Vac (380 to 440 Vac)
Range 4: N/A
60 Hertz Sensing
Range 1: 120 Vac (85 to 132 Vac)
Range 2: 240 Vac (170 to 264 Vac)
Range 3: 480 Vac (340 to 528 Vac)
Range 4: 600 Vac (540 to 660 Vac)
1-2 DECS-100 General Information 9287500991 Rev L
Accessory Input
Voltage Range: –3 Vdc to +3 Vdc
Setpoint Range: –30% to +30% shift
Burden: 1 k
Terminals: A, B

Communication Port
Interface: Full duplex RS-232
Connection: Rear panel DB-9 connector
Baud: 4800
Data Bits: 8
Parity: None
Stop Bit: 1

Contact Input Circuits

Type: Dry contacts
Interrogation Voltage: 13 Vdc (supplied by DECS-100)
Terminal Assignments for Standard Functions
Raise: 6U, 7
Lower: 6D, 7
Var/PF Enable: 52J, 52K
Parallel Control: 52L, 52M
Voltage Matching: VM, VMC

Common Alarm Output

Type: Form A
Rated Load: 7 Aac/Adc continuous
Make: 30 Aac/Adc, carry for 0.2 sec
Break: 7 Aac/0.1 Adc
Operating Voltage: 240 Vac/250 Vdc maximum
Terminals: AL1, AL2

Field Output
Continuous Rating: 63 Vdc, 7 Adc
Field Resistance: 9  minimum
Terminals: F+, F–
10 Second Forcing Rating
200 Vac Power Input: 135 Vdc, 15 Adc
110 Vac Power Input: 90 Vdc, 10 Adc (9 field)
75 Vdc, 15 Adc (5 field)

AVR Operating Mode

Adjustment Range: See Generator Voltage Sensing
Voltage Regulation: ±0.25% over load range at rated power factor and constant generator
frequency.
±0.5% with 3-phase sensing and shunt power at 40% THD of the voltage
waveform (due to a six SCR load).
Temperature Drift: ±0.5% for a 40C change
V/Hz Characteristic: Slope from 0 to 3PU is adjustable in 0.01PU increments. Transition
(Corner) frequency is adjustable from 40 to 65 Hz. See Figure 1-2 for the
V/Hz curves.
Response Time: Within 1 cycle

9287500991 Rev L DECS-100 General Information 1-3

 Figure 1-2. Typical V/Hz Curves

FCR (Manual) Operating Mode

Adjustment Range: 0 to 7 Adc
Increment: 0.01 Adc

Var Operating Mode (Optional)

Adjustment Range: –100 to 100%
Increment: 0.1%

PF Operating Mode (Optional)

Adjustment Range: 0.6 lag to 0.6 lead
Increment: 0.001

Parallel Compensation
Modes: Reactive Droop and Reactive Differential (cross-current)
Droop Adjust Range: 0 to 10%
Increment: 1%
 Burden can exceed 1 VA if external resistors are added to the CT circuit.

Field Overvoltage Protection

Pickup Range: 0 to 250 Vdc
Time Delay: 10 s (fixed)

Generator Overvoltage Protection

Pickup
Range: 100 to 120% of system voltage setting
Increment: 1.0%
Alarm Time Delay
Range: 0 to 10 s
Increment: 1s

1-4 DECS-100 General Information 9287500991 Rev L

Overexcitation Limiter
Pickup
Range: 0 to 15 Adc
Increment: 0.001 Adc
Alarm Time Delay
Range: 0 to 10 s
Increment: 1s

Underexcitation Limiter
Pickup
Range: 0 to 100% of rated vars
Increment: 1%
Alarm Time Delay
Range: 0 to 10 s
Increment: 1s

Soft Start Function (AVR Mode Only)

Time Adjust Range: 1 to 7,200 s
Increment: 1s

Voltage Matching
Accuracy: Generator rms voltage is matched with the bus rms voltage to within
±0.5% of the generator voltage.
Time Adjustment
Range: 1 to 300 s
Increment: 0.01 s

Metering (BESTCOMS)
Generator Voltage
Range: 10 V to 79 kV
Accuracy: ±0.5% (at 25C)
Generator Current
Range: 0.04 to 3,000 Aac for 1 A CT (Not to exceed nominal CT rating)
0.2 to 15,000 Aac for5 A CT (Not to exceed nominal CT rating)
Accuracy: ±0.5% (at 25C)
Frequency
Range: 40 to 65 Hz
Accuracy: ±0.2 Hz (at 25C)
Field Voltage
Range: 0 to 200 Vdc
Accuracy: ±5.0% (at 25C)
Field Current
Range: 0 to 20 A
Accuracy: ±0.5% (at 25C)
Bus Voltage
Range: 10 V to 79 kV
Accuracy: ±0.5% (at 25C)
Auxiliary DC Input
Range: –3 V to +3 V
Accuracy: ±0.5% (at 25C)
9287500991 Rev L DECS-100 General Information 1-5
Power (Apparent, Real, and Reactive)
Range: 0 to 99 MVA, MW, Mvar
Accuracy: ±3.0% (at 25C)
Power Factor
Range: –1.0 to –0.6, +0.6 to +1.0
Accuracy: ±0.02 at rated current (25C), CT input 10% nominal rating
Phase Angle
Range: 0 to 360 degrees
Accuracy: ±2.0 degrees (at 25C), CT input 10% nominal rating
Environment
Operating Temperature
DECS-100: –40 to 70C (–40 to 158F)
Storage Temperature
DECS-100: –40 to 85C (–40 to 185F)
CD-ROM: 0 to 50C (32 to 122F)
Type Tests
Shock: Withstands 20 G in three perpendicular planes
Vibration: Withstands 1.2 G at 5 to 26 Hz
Withstands 0.914 mm (0.036 in) double amplitude at 27 to 52 Hz
Withstands 5 G at 53 to 500 Hz
Salt Fog: Qualified per MIL-STD-810E
Physical
Weight
Unit: 1.10 kg (2.42 lb)
Shipping: 1.31 kg (2.88 lb)
Shipping Carton Dimensions (W x H x D)
Single Unit: 299 x 79 x 146 mm (11.75 x 3.125 x 5.75 in)
48 Units: 841 x 653 x 352 mm (33.13 x 25.69 x 13.88 in)
Maritime Recognition
Recognized per standard IACS E10 (Base document: IEC 60092-504) by the following:
 Bureau Veritas (BV)
 Det Norske Veritas (DNV)
 Germanischer Lloyd (GL)
Additional conditions must be met in order to comply with maritime agency standards, see Section 4,
Installation for further instructions.
UL Recognition
UL recognized per standard 508, UL file number E97035.
CSA Certification
Certified per CSA Standard CAN/CSA-C22.2 No. 14, CSA File No. LR23131.
CE Compliance
The DECS-200 meets the criteria set forth by the following EC Directives:
Low Voltage Directive (LVD) Harmonized Standard:
BS EN 50178 – Electronic Equipment for use in Power Installations
Electromagnetic Compatibility (EMC) Harmonized Standard:
BS EN 61000-6-2 – Electromagnetic Compatibility (EMC) Immunity for Industrial Environments
BS EN 61000-6-4 – Electromagnetic Compatibility (EMC) Emissions Standard for Industrial Environments

1-6 DECS-100 General Information 9287500991 Rev L

SECTION 2  HUMAN-MACHINE INTERFACE
TABLE OF CONTENTS
SECTION 2  HUMAN-MACHINE INTERFACE ....................................................................................... 2-1
INTRODUCTION.................................................................................................................................... 2-1
FRONT PANEL INDICATORS............................................................................................................... 2-1
Overexcitation Shutdown ................................................................................................................... 2-1
Generator Overvoltage ....................................................................................................................... 2-1
Loss of Generator Sensing................................................................................................................. 2-1
Overexcitation Limiting ....................................................................................................................... 2-2
Underexcitation Limiting ..................................................................................................................... 2-2
Var/P.F. Mode Active ......................................................................................................................... 2-2
Manual Mode Active ........................................................................................................................... 2-2
Underfrequency Active ....................................................................................................................... 2-2
COMMUNICATION PORT ..................................................................................................................... 2-2

Figures
Figure 2-1. DECS-100 Front Panel Indicators ........................................................................................... 2-1
Figure 2-2. DECS-100 Communication Port Location............................................................................... 2-2

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ii DECS-100 Human-Machine Interface 9287500991 Rev L

SECTION 2  HUMAN-MACHINE INTERFACE
INTRODUCTION
The DECS-100 human-machine interface (HMI) consists of front panel indicators and a rear-panel
communication port.

FRONT PANEL INDICATORS

DECS-100 front panel indicators consist of eight red LEDs. The indicators are shown in Figure 2-1 and
described in the following paragraphs.

Figure 2-1. DECS-100 Front Panel Indicators

Overexcitation Shutdown
This LED lights when the Overexcitation Protection feature is enabled and the field voltage exceeds the
adjustable setpoint for 10 seconds. The DECS-100 will shutdown when an overexcitation condition is
detected. The Overexcitation Shutdown LED will light for 5 seconds when the DECS-100 is powered up
following an overexcitation shutdown.

Generator Overvoltage
This LED lights when generator output voltage exceeds the adjustable setpoint for 0.75 seconds. When a
generator overvoltage condition exists, the DECS-100 output contacts close and the DECS-100 shuts
down (if hardware shutdown is enabled). The Generator Overvoltage LED will light for 5 seconds when
the DECS-100 is powered up following a generator overvoltage shutdown.

Loss of Generator Sensing

This LED lights when a loss of generator sensing voltage is detected. When a loss of sensing condition
occurs, the DECS-100 output contacts close. Depending on the protective action selected, the DECS-100
will either shutdown or transfer to Manual mode. The Loss of Generator Sensing LED will flash for 5
seconds when the DECS-100 is powered up following a loss of generator sensing shutdown.

9287500991 Rev L DECS-100 Human-Machine Interface 2-1

Overexcitation Limiting
This LED lights when the field current exceeds the programmed overexcitation limit. It stays lit until the
overexcitation condition ceases or the overexcitation time delay expires and the DECS-100 shuts down.
The Overexcitation Limiting LED will flash for 5 seconds when the DECS-100 is powered up following an
overexcitation limiting shutdown.

Underexcitation Limiting
This LED lights when the sensed, reactive power (leading vars) decreases below the programmed
underexcitation limit. It stays lit until the underexcitation condition ceases or the underexcitation time
delay expires and the DECS-100 shuts down. The Underexcitation Limiting LED will flash for 5 seconds
when the DECS-100 is powered up following an underexcitation limiting shutdown.

Var/P.F. Mode Active

This LED lights to indicate that the DECS-100 is operating in the optional Var or Power Factor mode of
control. Var/Power Factor control is enabled through BESTCOMS software and when the 52J/K contact
input is open.

Manual Mode Active

This LED lights when the DECS-100 is operating in Manual mode. Manual mode is enabled through
BESTCOMS software.

Underfrequency Active
This LED lights when the generator frequency decreases below the underfrequency setpoint and the
DECS-100 is regulating on the selected volts per hertz curve.

COMMUNICATION PORT
The communication port is located on the rear panel and
consists of a female, RS-232 (DECS-B-9) connector. The
communication port serves as an interface for programming
(setup) of the DECS-100. Figure 2-2 illustrates the location of
the communication port.
Programming requires a standard, nine-pin, serial
communication cable connected between the DECS-100 and
an IBM-compatible PC operating with BESTCOMS software.
BESTCOMS software is a Microsoft Windows®-based
communication software package that is supplied with the
DECS-100. A detailed description of BESTCOMS is provided
in Section 5, BESTCOMS Software.

WARNING!
Lethal voltage is present at the rear panel when the unit is
energized. Rear panel connections should be made only
when the unit is de-energized.

Figure 2-2. DECS-100

Communication Port Location

2-2 DECS-100 Human-Machine Interface 9287500991 Rev L

SECTION 3  FUNCTIONAL DESCRIPTION
TABLE OF CONTENTS
SECTION 3  FUNCTIONAL DESCRIPTION ........................................................................................... 3-1
INTRODUCTION.................................................................................................................................... 3-1
DECS-100 FUNCTION BLOCKS........................................................................................................... 3-1
Analog Input Circuits .......................................................................................................................... 3-1
Bus Voltage .................................................................................................................................... 3-1
Generator Voltage .......................................................................................................................... 3-1
B-Phase Line Current ..................................................................................................................... 3-2
Accessory Input (Auxiliary Adjust) .................................................................................................. 3-2
Field Voltage ................................................................................................................................... 3-2
Field Current ................................................................................................................................... 3-2
Contact Input Circuits ......................................................................................................................... 3-2
Raise ............................................................................................................................................... 3-2
Lower .............................................................................................................................................. 3-2
Var/Power Factor Control (52J/K) Option ....................................................................................... 3-2
Parallel Generator Compensation (52L/M) ..................................................................................... 3-2
Voltage Matching Control Option .................................................................................................... 3-3
RS-232 Communication Port.............................................................................................................. 3-3
Microprocessor ................................................................................................................................... 3-3
Power Input Stage .............................................................................................................................. 3-3
Power Supply ..................................................................................................................................... 3-3
Power Amplifier Stage ........................................................................................................................ 3-3
Front Panel Indicators ........................................................................................................................ 3-3
Relay Output....................................................................................................................................... 3-3
DECS-100 OPERATING FEATURES ................................................................................................... 3-3
Operating Modes ................................................................................................................................ 3-3
Automatic Voltage Regulation Mode .............................................................................................. 3-3
Manual Mode .................................................................................................................................. 3-4
Var Control Mode (Optional) ........................................................................................................... 3-4
Power Factor Control Mode (Optional) ........................................................................................... 3-4
Reactive Droop Compensation .......................................................................................................... 3-4
Underfrequency .................................................................................................................................. 3-4
Protection ........................................................................................................................................... 3-5
Generator Overvoltage ................................................................................................................... 3-5
Loss of Sensing Voltage ................................................................................................................. 3-5
Field Overvoltage (Overexcitation Shutdown) ................................................................................ 3-5
Limiters ............................................................................................................................................... 3-6
Overexcitation Limiting ................................................................................................................... 3-6
Underexcitation Limiting ................................................................................................................. 3-6
Soft Start............................................................................................................................................. 3-6
Voltage Matching (Optional) ............................................................................................................... 3-7

Figures
Figure 3-1. Simplified DECS-100 Block Diagram ...................................................................................... 3-1

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ii DECS-100 Functional Description 9287500991 Rev L

SECTION 3  FUNCTIONAL DESCRIPTION
INTRODUCTION
This section describes how the DECS-100 functions and explains its operating features. To ease
understanding, DECS-100 functions are illustrated in the block diagram of Figure 3-1. A detailed
description of each function block is provided in the paragraphs under the heading of DECS-100 Function
Blocks.
DECS-100 operating features include four operating modes, four protective functions, startup provisions,
reactive droop compensation, underfrequency compensation, and optional voltage matching. A detailed
description of each operating feature is provided in the paragraphs under the heading of DECS-100
Operating Features.

Figure 3-1. Simplified DECS-100 Block Diagram

DECS-100 FUNCTION BLOCKS

The following paragraphs describe each of the function blocks illustrated in Figure 3-1. The function of
each block is explained along with the operation of all function block inputs and outputs.

Analog Input Circuits

Seven analog voltages and current may be sensed and applied to the DECS-100.
Bus Voltage
C-phase and A-phase bus voltages are monitored at terminals B3 and B1 on units that include voltage
matching. Nominal voltages of up to 600 Vac may be sensed at these terminals. Voltage monitored at this
input is scaled and conditioned before being applied to the input of the analog-to-digital converter (ADC).
This bus voltage signal applied to the ADC is used to calculate the rms value of the bus voltage across
phases C and A (Bus VC-A).
Generator Voltage
Generator voltage is monitored at terminals E1 (A-phase), E2 (B-phase), and E3 (C-phase). Nominal
voltages of up to 600 Vac may be sensed at these terminals. Voltage applied to these inputs is scaled
9287500991 Rev L DECS-100 Functional Description 3-1
and conditioned before being applied to the input of the ADC. The voltage signal from phase C and A
(VC-A) of the generator is used by the ADC to calculate the rms value of generator voltage across phases
C and A. Likewise, the voltage signal from phase C and B (VC-B) of the generator is used by the ADC to
calculate the rms value of generator voltage across phases C and B. The rms value of generator phase B
to phase A voltage (VB-A) is calculated by the microprocessor from the phase C to phase A signal (VC-A)and
the phase C to phase B (VC-B) signal.
Additionally, the generator phase C to phase A (VC-A) signal is applied to a filtered, zero-cross detector
circuit. This signal is applied to the microprocessor and is used to calculate generator frequency.
B-Phase Line Current
The phase B line current (IB) signal is developed through a customer supplied current transformer (CT)
and monitored through terminals CT1 and CT2. Depending on the option selected, current up to 1 ampere
(style number xx1) or 5 amperes (style number xx5) rms may be monitored at these terminals. The
current monitored at these terminals is scaled and conditioned by an internal current transformer and
active circuitry for use by the ADC. The signal applied to the ADC is used to calculate the rms value of
phase B line current.
Additionally, the phase angle between phase B line current and phase C to phase A generator voltage is
calculated for use during droop and var/power factor operation.
Accessory Input (Auxiliary Adjust)
This input allows adjustment of the DECS-100 regulation setpoint by the application of a positive or
negative dc voltage across terminals A and B. Positive voltage applied to terminal A with respect to
terminal B will cause the active mode setpoint to increase. Voltage from –3 to +3 Vdc may be applied to
this input. The circuit induces a 1,000-ohm burden on the dc source. The Application of a ±3 Vdc signal
corresponds to a ±30 percent change in setpoint.
Field Voltage
Voltage (VFIELD) across the regulator field output terminals, F+ and F–, is monitored, scaled, and
conditioned before being applied to the ADC. This signal is used to calculate the dc value of field voltage
for use in system protection.
Field Current
Current (IFIELD) through the main power output switch is converted to a proportional voltage level. This
voltage signal is scaled and conditioned before being applied to the input of the ADC. The result is used
to calculate the dc value of field current for use in the Manual mode of operation as well as protection of
the system.

Contact Input Circuits

Five contact input circuits powered from an internal 13 Vdc power supply provide input control from user-
supplied, isolated, dry-type contacts.
Raise
Closing a contact across terminals 6U and 7 causes the active operating setpoint to increase. This
function is active as long as the contact is closed.
Lower
Closing a contact across terminals 6D and 7 causes the active operating setpoint to decrease. This
function is active as long as the contact is closed.
Var/Power Factor Control (52J/K) Option
Closing a contact across terminals 52J and 52K disables var/power factor control. An open contact
enables the DECS-100 to control the generator reactive power in either the var or the power factor mode.
The contact has no effect when this function is not enabled in the software. For more information, see
Parallel Generator Compensation (52L/M) and Voltage Matching Control Option.
Parallel Generator Compensation (52L/M)
Closing a contact across terminals 52L and 52M disables parallel operation. An open contact enables
parallel operation and the DECS-100 operates in reactive droop compensation mode.

3-2 DECS-100 Functional Description 9287500991 Rev L

If the Var/Power Factor Control option is present and is enabled in the software, the 52J/K input has
priority. Therefore, if the 52J/K and the 52L/M inputs are both open, the system operates in var/power
factor mode. For more information, see Voltage Matching Control Option.
Voltage Matching Control Option
If the Voltage Matching option is enabled in the software, closing a contact across terminals VM and VMC
causes the DECS-100 to operate in the voltage matching mode. An open contact disables voltage
matching. Voltage matching is also disabled when either the 52J/K or 52L/M inputs are open.

RS-232 Communication Port

The communication port provides the interface for user programming (setup) of the DECS-100.
Connection is made to the female RS-232 (DB-9) connector with a user-supplied, standard 9-pin cable.
The communication port is optically isolated and is powered from a transformer-isolated supply.

Microprocessor
The microprocessor is the heart of the DECS-100 and performs measurement, computation, control, and
communication functions by the use of its embedded programming and the nonvolatile settings stored in
its memory.

Power Input Stage

Input power applied to terminals 3, 4, and 5 is rectified and filtered before being applied to the power
amplifier and the power supply. Input power may be single-phase or three-phase in the range of 88 to 250
Vac at a frequency of 50 to 400 hertz.
The input power source should be properly fused for the application.

Power Supply
The internal switch-mode power supply receives power from the power input stage and supplies power at
the required dc voltage levels to the internal circuitry of the DECS-100.

Power Amplifier Stage

The power amplifier receives power from the power input stage and supplies a controlled amount of
power to the exciter field via terminals F+ and F–. The amount of power supplied to the exciter field is
based on gating pulses received from the microprocessor. The power amplifier uses a solid state power
switch to provide the required power to the exciter field. Power amplifier output to the field is rated up to
63 Vdc at 7 Adc continuous and 135 Vdc at 15 Adc for 10 seconds.

Front Panel Indicators

Eight front-panel LED indicators light to indicate various protective functions and operating modes.
Section 2, Human-Machine Interface provides more information about the front panel indicators.

Relay Output
A common alarm output contact is provided through terminals AL1 and AL2. This normally open, form A
contact annunciates alarm or trip conditions. The relay output is non-latching.

DECS-100 OPERATING FEATURES

The following paragraphs describe the characteristics of each DECS-100 operating feature.

Operating Modes
The DECS-100 provides up to four modes of operation selectable through BESTCOMS software.
Automatic voltage regulation mode and Manual mode are standard features. Var and Power Factor
modes are an option.
Automatic Voltage Regulation Mode
In Automatic Voltage Regulation (AVR) mode, the DECS-100 regulates rms generator output voltage.
This is accomplished by sensing generator output voltage and adjusting dc output excitation current to
maintain voltage at the regulation setpoint. The regulation setpoint is adjusted by the Raise and Lower

9287500991 Rev L DECS-100 Functional Description 3-3

contact inputs, the Accessory input, or through BESTCOMS software. The regulation point may also be
modified by the Droop function or the Underfrequency function under certain conditions.
Manual Mode
In Manual mode, also known as Field Current Regulation (FCR) mode, the DECS-100 maintains dc
excitation current at a set level. The current-level setpoint is adjustable from 0 to 7 Adc in 0.01 Adc
increments by the Raise and Lower contact inputs, the optional Accessory input, or through BESTCOMS
software.

CAUTION
The Manual mode excitation level must be evaluated prior to enabling this
feature. If the level of excitation current is inappropriate for the generator, severe
damage to the generator may occur.

Var Control Mode (Optional)

In Var Control mode, the DECS-100 maintains generator vars (volt-amperes, reactive) at a set level when
paralleling with an infinite bus. The DECS-100 calculates generator vars by using the sensed generator
output voltage and current quantities. It then adjusts the dc excitation current to maintain vars at the
setpoint. Var control is enabled and disabled through BESTCOMS software. When the software is turned
on, var control is enabled or disabled through the Var/Power Factor Control (52J/K) contact input circuit.
The var setpoint is adjustable from 100 percent absorb to 100 percent generate through the Raise and
Lower contact inputs, the optional Accessory input, or through BESTCOMS software.
Power Factor Control Mode (Optional)
In Power Factor Control mode, the DECS-100 maintains generator power factor at a set level when
paralleling with an infinite bus. The DECS-100 calculates generator power factor using the sensed
generator output voltage and current quantities and then adjusts the dc excitation current to maintain
power factor at the setpoint. Power factor control is enabled or disabled through BESTCOMS software.
When the software is turned on, it is enabled or disabled through the Var/Power Factor Control (52J/K)
contact input circuit. The power factor setpoint is adjustable between 0.6 lag and 0.6 lead through the
Raise and Lower contact inputs, the optional Accessory input, or through BESTCOMS software.

Reactive Droop Compensation

The DECS-100 provides a reactive droop compensation feature to assist in the sharing of reactive load
during parallel generator operation. When this feature is enabled, the DECS-100 calculates the reactive
portion of the generator load using the sensed generator output voltage and current quantities and then
modifies the voltage regulation setpoint accordingly. A unity power factor generator load results in almost
no change in generator output voltage. A lagging power factor generator load (inductive) results in a
reduction of generator output voltage. A leading power factor generator load (capacitive) results in an
increase of generator output voltage. Droop is adjustable up to 10 percent with rated, nominal B-phase
line current (1 ampere or 5 amperes applied through terminals CT1 and CT2) and 0.8 power factor. The
droop feature is enabled and disabled through the Parallel Generator Compensation contact input circuit
(terminals 52L and 52M). Droop is also disabled when operating in var or power factor control modes.

Underfrequency
When generator frequency drops below the selected knee frequency setpoint, the voltage setpoint is
automatically adjusted by the DECS-100 so that generator voltage follows the selected PU (per unit) V/Hz
curve. When operating on the selected PU V/Hz curve, the Underfrequency Active indicator lights on the
front panel and in BESTCOMS. Underfrequency control is disabled below 12 hertz. The knee frequency is
adjustable from 40 to 65 hertz in 0.1 hertz increments and the PU V/Hz curve may be set at a slope of 0
to 3 in 0.01 steps through BESTCOMS software. A slope of 0 effectively disables the underfrequency
function. The DECS-100 has a minimum regulation point of approximately 30 percent of the nominal
setpoint.

3-4 DECS-100 Functional Description 9287500991 Rev L

Protection
The DECS-100 includes three protective functions: generator overvoltage, loss of sensing voltage, and
field overvoltage. Each protective function has a corresponding front panel indicator that lights when the
function is active. An active protective function is also annunciated through BESTCOMS.
Generator Overvoltage
A generator overvoltage condition can be configured (in BESTCOMS) to close the DECS-100 relay
output, disable the DECS-100, initiate both actions, or initiate neither action. When the sensed generator
voltage increases above the adjustable voltage level setpoint for the duration of the adjustable alarm time
delay, the DECS-100 initiates the selected action.
If the DECS-100 is configured to close the relay output, a generator overvoltage condition will light the
front panel and BESTCOMS Generator Overvoltage indicator and close the relay output at terminals AL1
and AL2.
If the DECS-100 is configured for hardware shutdown, a generator overvoltage condition will disable the
DECS-100 after the alarm time delay expires. When the DECS-100 is powered up following a generator
overvoltage shutdown, the Generator Overvoltage indicator will light for five seconds.
The voltage level setpoint is adjustable from 100 to 120 % of the system voltage setting. The alarm time
delay is adjustable from 0 to 10 seconds.
Loss of Sensing Voltage
The DECS-100 monitors the sensed generator output voltage and takes protective action if a loss of
sensing voltage is detected. A loss of sensing voltage is detected during the following conditions.
 The sensed voltage is less than 50 percent of the rated voltage (one-phase or three-phase sensing).
 A total loss of any phase occurs (three-phase sensing).
 The voltage difference between any phase (line-to-line) and the three-phase average exceeds 20
percent of nominal (three-phase sensing).
A time delay of 0 to 25 seconds is adjustable through BESTCOMS software. This delays the protective
action in order to allow field forcing in applications that do not sense B-phase generator current. The
default time delay setting is 10 seconds.
BESTCOMS software allows the selection of one of two protective actions for a loss of sensing. Either a
complete shutdown or a transfer to Manual mode may be selected.
If shutdown is selected and a loss of sensing occurs, the Loss of Generator Sensing indicator on the front
panel and in BESTCOMS lights, the relay output closes, and the DECS-100 shuts down after the
adjustable time delay expires. When the DECS-100 is powered up following a loss of generator sensing
shutdown, the Loss of Generator Sensing indicator will light for five seconds. However, if the loss of
sensing conditions still exists, the DECS-100 will not shut down due to loss of sensing until the soft-start
time delay and the loss of sensing time delay expires.
If transfer to Manual is selected and a loss of sensing occurs, the relay output closes, and the DECS-100
transfers to the Manual mode of operation after the adjustable time delay expires. The DECS-100 will
remain in this mode of operation until switched via BESTCOMS. Prior to selecting transfer to Manual on
loss of sensing, it is necessary to determine an appropriate Manual (FCR) mode setpoint level to be
transferred to. An inappropriate excitation level could result in severe damage to equipment.
This function is disabled when the frequency decreases below 12 hertz or when a generator short circuit
condition is detected. A generator short-circuit is determined when the B-phase CT current exceeds three
times the per unit value. Loss of sensing shutdown or transfer is not active during the soft-start time.
Field Overvoltage (Overexcitation Shutdown)
A field overvoltage condition can be configured (in BESTCOMS) to close the DECS-100 relay output,
disable the DECS-100, initiate both actions, or initiate neither action. When the field voltage increases
above the adjustable voltage level setpoint for the fixed duration of 10 seconds, the DECS-100 initiates
the selected action.
If the DECS-100 is configured to close the relay output, a field overvoltage condition will light the front
panel and BESTCOMS Overexcitation Shutdown indicator and close the relay output at terminals AL1
and AL2.
If the DECS-100 is configured for hardware shutdown, a field overvoltage condition will disable the DECS-
100 after the 10 second time delay expires. When the DECS-100 is powered up following a field
overvoltage shutdown, the Overexcitation Shutdown indicator will light for five seconds.
9287500991 Rev L DECS-100 Functional Description 3-5
The voltage level setpoint is adjustable from 0 to 250 Vdc. The field overvoltage time delay is fixed at 10
seconds.

Limiters
DECS-100 limiters consist of an overexcitation limiter (OEL) triggered by an increase in field current and
an underexcitation limiter (UEL) triggered by excessive leading vars.
Overexcitation Limiting
The DECS-100 provides two types of overexcitation limiting: summing point and takeover.
Summing Point OEL. When the level of field current increases above the adjustable current level setpoint,
the front panel and BESTCOMS Overexcitation Limiting indicators light. If the overexcitation condition
persists for the duration of the user-adjustable alarm time delay, the relay output at terminals AL1 and
AL2 closes.
The advantage of a summing-point type of OEL is that it can provide a smooth transition into and out of
the limit. Its drawback is that it does not control field current directly, but has to work through the normal
voltage regulator, and may be influenced by changes in terminal voltage.
Takeover OEL. When takeover-style overexcitation limiting is used, the level of field current at which
limiting occurs is determined by an adjustable current level setpoint. If the field current increases above
the adjustable current level setpoint, the front panel and BESTCOMS Overexcitation Limiting indicators
light and the field current is limited and forced to follow the inverse time curve.
The advantage of a takeover type of OEL is that it provides direct control of the exciter field current
without relying on the normal voltage regulator’s control action. Its drawback is that it may not provide a
smooth transition into and out of the limit.
If hardware shutdown is enabled, the DECS-100 will be disabled when the time delay expires. When the
DECS-100 is powered up following a shutdown triggered by overexcitation limiting, the Overexcitation
Limiting indicator will light for five seconds.
The current level setpoint is adjustable from 0 to 15 Adc. The alarm time delay is adjustable from 0 to 10
seconds.
Underexcitation Limiting
When the level of leading vars increases above the adjustable var level setpoint, the front panel and
BESTCOMS Underexcitation Limiting indicators light. If the underexcitation condition persists for the
duration of the adjustable alarm time delay, the relay output at terminals AL1 and AL2 closes.
If hardware shutdown is enabled, the DECS-100 will be disabled when the time delay expires. When the
DECS-100 is powered up following a shutdown triggered by underexcitation limiting, the Underexcitation
Limiting indicator will light for five seconds.

The var level setpoint is adjustable from 0 to 100% of the rated vars. The rated var level is determined by
the following equation:
rated var level  V AVG  I B  3
where IB is the DECS-100 nominal current sensing rating (1 Aac or 5 Aac)
The alarm time delay is adjustable from 0 to 10 seconds.

NOTE
The UEL function is active only during parallel operation when the 52J/K contact
input or 52L/M contact input is open.

Soft Start
The DECS-100 also incorporates an adjustable soft start feature that controls the time for generator
voltage or field current to ramp to the regulation setpoint. The ramp rate is adjustable from 1 to 7,200
seconds in 1 second increments through BESTCOMS. The underfrequency feature is also active during
soft start and takes priority in control of the generator voltage in an effort to minimize voltage overshoot.

3-6 DECS-100 Functional Description 9287500991 Rev L

Voltage Matching (Optional)
Voltage matching is useful when the PT ratios in an application are not matched exactly. Using
BESTCOMS to enter the generator PT ratio and bus PT ratio will automatically compensate for the offset.
The DECS-100 voltage matching option automatically matches the rms generator output with the rms bus
voltage prior to synchronizing. The DECS-100 compares and matches the generator voltage with the bus
voltage by adjusting the dc excitation current. Voltage matching is enabled when the bus voltage is within
10% of the nominal sensing range selected. As long as the values of generator and bus voltage (applies
to the DECS-100 voltage sensing inputs) are within the acceptable range, voltage matching can be
achieved.
The rate at which the DECS-100 matches the generator input level with the bus input level is controlled by
a voltage matching speed setting. this setting is adjustable from 1 to 300 seconds in 0.01 second
increments.
Voltage matching can be disabled by the state of the DECS-100 contact inputs. In BESTCOMS, the
52J/K contact input, 52L/M contact input, or both contact inputs can be configured to enable and disable
voltage matching. To enable bus voltage matching, select 52J/K. This will allow droop to remain active.
When the utility tie breaker closes, voltage matching will be disabled automatically (via the 52J/K contact
input) and var/power factor control will be enabled.
Two voltage matching modes are available: Maintain and Revert. When Maintain mode is implemented,
the DECS-100 setpoint is maintained at the bus voltage level even when the generator or utility breaker is
open. When Revert mode is implemented, the DECS-100 setpoint reverts to its original level when the
generator or utility breaker opens. Revert is the default voltage matching mode.

9287500991 Rev L DECS-100 Functional Description 3-7

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3-8 DECS-100 Functional Description 9287500991 Rev L

SECTION 4  INSTALLATION
TABLE OF CONTENTS
SECTION 4  INSTALLATION .................................................................................................................. 4-1
INTRODUCTION.................................................................................................................................... 4-1
MOUNTING............................................................................................................................................ 4-1
CONNECTIONS..................................................................................................................................... 4-4
DECS-100 Terminations .................................................................................................................... 4-4
Bus Voltage Sensing Inputs (Optional) .............................................................................................. 4-5
Generator Voltage Sensing Inputs ..................................................................................................... 4-5
Phase B Line Current Sensing Input .................................................................................................. 4-5
Accessory Input .................................................................................................................................. 4-5
Raise and Lower Contact Inputs ........................................................................................................ 4-5
Var/Power Factor Control Contact Input (Optional) ........................................................................... 4-5
Parallel Generator Compensation ...................................................................................................... 4-5
Parallel Control and Var/PF Control Inputs ........................................................................................ 4-6
Voltage Matching (Optional) ............................................................................................................... 4-6
Power Supply Inputs .......................................................................................................................... 4-6
Chassis Ground .................................................................................................................................. 4-6
Power (Field) Output .......................................................................................................................... 4-6
Relay Output (Alarm) .......................................................................................................................... 4-6
Communication Port ........................................................................................................................... 4-7
DECS-100 Connections for Typical Applications ............................................................................... 4-7
INSTALLATION FOR CE COMPLIANCE ............................................................................................ 4-13
Mounting ........................................................................................................................................... 4-13
Wiring ............................................................................................................................................... 4-13
PRELIMINARY SETUP........................................................................................................................ 4-14
Operating Power Considerations During DECS-100 Programming................................................. 4-15
ADJUSTMENTS................................................................................................................................... 4-15

Figures
Figure 4-1. DECS-100 Dimensions ........................................................................................................... 4-2
Figure 4-2. Cutout and Drilling Dimensions ............................................................................................... 4-3
Figure 4-3. DECS-100 Terminals .............................................................................................................. 4-4
Figure 4-4. RS-232 Port Pin Assignments ................................................................................................ 4-7
Figure 4-5. Personal Computer to DECS-100 Connections ...................................................................... 4-7
Figure 4-6. Typical Connections for PMG Application with ABC Rotation and Three-Phase Sensing ..... 4-8
Figure 4-7. Typical Connections for PMG Application with ABC Rotation and Single-Phase Sensing .... 4-9
Figure 4-8. Typical Connections for Shunt Application with ABC Rotation and Three-Phase Sensing .. 4-10
Figure 4-9. Typical Connections for Shunt Application with ABC Rotation and Single-Phase Sensing . 4-11
Figure 4-10. Typical Connections for Station Power Application and Three-Phase Sensing ................. 4-12
Figure 4-11. Cross-Current (Reactive Differential) Connections ............................................................. 4-13
Figure 4-12. Operating Power Connections for DECS-100 Programming (Input Voltage >120 Vac)..... 4-14

Tables
Table 4-1. Bus Voltage Sensing Terminals ............................................................................................... 4-5
Table 4-2. Generator Voltage Sensing Terminals ..................................................................................... 4-5
Table 4-3. 52L/"M" and 52J/K Control Modes ........................................................................................... 4-6
Table 4-4. Communication Port Pin Functions .......................................................................................... 4-7

9287500991 Rev L DECS-100 Installation i

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ii DECS-100 Installation 9287500991 Rev L

SECTION 4  INSTALLATION
INTRODUCTION
DECS-100 Digital Excitation Control Systems are delivered in sturdy cartons to prevent shipping damage.
Upon receipt of a system, check the part number against the requisition and packaging list for agreement.
Inspect for damage, and if there is evidence of such, immediately file a claim with the carrier and notify
the Basler Electric Regional Sales Office, your Sales Representative or a Sales Representative at Basler
Electric, Highland, Illinois.
If the unit is not installed immediately, store it in the original shipping package in a moisture and dust free
environment.

MOUNTING
The DECS-100 is normally located in the generator conduit box. It is designed for behind the panel
mounting and requires a cutout for front panel viewing. Supplied mounting hardware consists of six #12
thread-forming screws that pass through mounting holes in the conduit box and thread into the plastic
shell of the DECS-100. The recommended torque range for the steel mounting screws is 4.07 to 4.52
newton-meters (36 to 40 inch-pounds). The unit must be mounted where the ambient temperature does
not exceed the allowable environmental conditions called out in Section 1, General Information,
Specifications. DECS-100 package dimensions are shown in Figure 4-1. Cutout and drilling dimensions
are shown in Figure 4-2. Drawing dimensions are shown in inches and millimeters (in parenthesis).

9287500991 Rev L DECS-100 Installation 4-1

 Figure 4-1. DECS-100 Dimensions

4-2 DECS-100 Installation 9287500991 Rev L

 Figure 4-2. Cutout and Drilling Dimensions
9287500991 Rev L DECS-100 Installation 4-3
CONNECTIONS
DECS-100 connections are dependent on the application and excitation scheme. Incorrect wiring may
result in damage to the unit. Check the part number to ensure that you have the correct unit before
connecting and applying power.

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

DECS-100 Terminations
DECS-100 units have two types of interface terminals (Figure 4-3). One type is quarter-inch, quick-
connect terminals and the other is a 9-pin DB9 connector. All terminals are located on the rear of the unit.
The quarter-inch, quick-connect terminal labels are located on the rear of the case. Wires performing
common functions, such as voltage sensing leads, should be grouped together. The 9-pin DB-9 type
connector is used for temporary interface with both IBM compatible PCs and hand-held computers.
Figure 4-3 shows the terminal connections located on the rear panel of the DECS-100. Except as noted
above, connections should be made with minimum wire size of 14 AWG.

Figure 4-3. DECS-100 Terminals

4-4 DECS-100 Installation 9287500991 Rev L

Bus Voltage Sensing Inputs (Optional)
The bus voltage sensing terminals are labeled B1 and B3. These terminals are used only on units that
include the Voltage Matching option. The bus input is not phase sensitive to generator sensing. Table 4-1
lists the terminal assignments for bus voltage sensing.
Table 4-1. Bus Voltage Sensing Terminals
Bus Voltage Phase Terminal
A B1
C B3

Generator Voltage Sensing Inputs

The generator voltage sensing terminals are labeled E1, E2, and E3. The DECS-100 comes equipped for
three-phase sensing as standard. Single-phase sensing is obtained by connecting the C-phase sensing
input to terminals E2 and E3. Table 4-2 lists the terminal assignments for three-phase and single-phase
generator voltage sensing.
Table 4-2. Generator Voltage Sensing Terminals
Generator
Sensing Phase Terminal
A E1
3-Phase B E2
C E3
A E1
1-Phase
C E2, E3

Phase B Line Current Sensing Input

Generator line current is stepped down through a user-supplied current transformer (CT). Secondary
current from that transformer is applied to terminals labeled CT1 and CT2.

Accessory Input
The accessory input voltage terminals are labeled A and B and accept a maximum signal of ±3 Vdc.
Positive voltage applied to terminal A with respect to terminal B causes the active mode setpoint to
increase. For every 1 Vdc change, a 10% change in the active mode setpoint is achieved.

Raise and Lower Contact Inputs

Remote setpoint adjustment may be accomplished by connecting a single-pole, double-throw (SPDT),
spring return, center-off switch to the terminals labeled 6U, 7, and 6D. To connect this switch, the center
pole, or common terminal, must be connected to terminal 7. The other two terminals are connected to
terminals 6U and 6D.
This remote adjust switch may be mounted up to 150 feet away from the DECS-100 when using twisted,
shielded cable. Only dry, ungrounded switching contacts should be applied to the Raise and Lower
contact inputs.

Var/Power Factor Control Contact Input (Optional)

A customer-supplied enable/disable contact for this function connects to the terminals labeled 52J and
52K.
Only dry, ungrounded switching contacts should be applied to the Var/Power Factor Control contact input.

Parallel Generator Compensation

A customer-supplied enable/disable contact for this function connects to the terminals labeled 52L and
52M.
9287500991 Rev L DECS-100 Installation 4-5
Only dry, ungrounded switching contacts should be applied to the Parallel Generator Compensation
contact input.

Parallel Control and Var/PF Control Inputs

User-supplied contacts at terminals 52L and 52M determine whether AVR or Droop mode is active.
Terminals 52L and 52M typically connect to a 52b auxiliary contact of the generator breaker. User-
supplied contacts at terminals 52J and 52K control whether var or power factor correction is active or
disabled. Terminals 52J and 52K typically connect to the auxiliary contacts of the utility tie breaker. Table
4-3 lists the operating modes achieved for the different 52L/M and 52J/K contact states. A closed state
indicates a continuous contact closure and an open state indicates a continuous open-circuit.
Table 4-3. 52L/M and 52J/K Control Modes
DECS-100 Operating Mode 52L/M 52J/K Generator Operating Mode
AVR mode active, no droop, optional Closed Closed Single unit/stand-alone
var/PF mode disabled
Droop mode active, optional var/PF Open Closed Paralleled to the utility grid (droop) or
mode disabled two or more generators islanded
(droop or CCC)
Var/PF mode active Open Open Paralleled to utility grid

Voltage Matching (Optional)

A customer-supplied enable/disable contact for this function connects to the terminals labeled VM and
VMC. Only dry, ungrounded switching contacts should be applied to the Voltage Matching contact input.
Voltage matching is also enabled/disabled by the state of the 52J/K and/or 52L/M contact inputs. In
BESTCOMS, voltage matching can be configured to be disabled when the 52J/K or 52L/M contact input is
open or just the 52J/K contact input is open.

Power Supply Inputs

Power input terminals are labeled 3, 4, and 5. Single-phase or three-phase power may be applied. Single-
phase power may be applied to any two of the three terminals.
The DECS-100 can be powered directly from a variety of sources as long as the DECS-100 input power
specifications are followed (see Section 1, General Information, Specifications).
Examples of DECS-100 operating power sources are:
 Generator (shunt fed)
 Permanent magnet generator (PMG)
 Auxiliary winding
When powering the DECS-100 from a low-impedance power source, special provisions must be made to
avoid damage to the DECS-100. Examples of a low-impedance power source include a station service
source or power outlet. An Inrush Current Reduction Module, ICRM-7, must be connected between the
power source and DECS-100 input power terminals (see Figure 4-10). The ICRM-7 prevents DECS-100
damage by minimizing the level of inrush current. The ICRM-7 can also be used when programming the
DECS-100. However, the Preliminary Setup paragraphs illustrate an alternate method for temporarily
powering the DECS-100 for programming.
More details about the ICRM-7 are available in Basler Electric publication 9387900990.

Chassis Ground
The chassis ground terminal is labeled GND.

Power (Field) Output

The field output terminals for connection to the generator exciter field are labeled F+ and F–.

Relay Output (Alarm)

The common alarm relay output contact may be accessed at the terminals labeled AL1 AND AL2.

4-6 DECS-100 Installation 9287500991 Rev L

Communication Port
The RS-232 port on the rear panel uses a DB-9
female connector. Figure 4-4 Illustrates the pin
assignments of the communication port and
Table 4-4 Identifies the RS-232 connector pin
functions. A standard communication cable
terminated with a DB-9 male connector is used
for PC interface with the DECS-100 as shown in
Figure 4-5. Figure 4-4. RS-232 Port Pin Assignments

Table 4-4. Communication Port Pin Functions

Pin Function Name Direction
1 N/C — N/A
2 Transmit data TXD From DECS-100
3 Receive data RXD To DECS-100
4 N/C — N/A
5 Signal ground GND N/A
6 N/C — N/A
7 N/C — N/A
8 N/C — N/A
9 N/C — N/A

Figure 4-5. Personal Computer to DECS-100 Connections

DECS-100 Connections for Typical Applications

Figures 4-6 through 4-10 illustrate typical applications using the DECS-100. Figure 4-6 shows an
application where DECS-100 operating power is derived from a permanent magnet generator (PMG) and
three-phase voltage sensing is applied to the DECS-100. Figure 4-7 shows another PMG application but
with single-phase voltage sensing. Figure 4-8 shows an application where DECS-100 operating power is
derived from the generator output (shunt application) and three-phase voltage sensing is applied to the
DECS-100. Figure 4-9 shows another shunt application but with single-phase sensing. Figure 4-10 shows
a DECS-100 powered by single-phase station power in a three-phase sensing application.
Figure 4-11 shows a typical connection diagram for two paralleled generators operating in cross-current
compensation (reactive differential) mode. The resistors shown have a value of 0.1 ohms. This is a typical
value that can be used to set the burden. (Ensure that the resistor power rating is adequate for the
installation.)

9287500991 Rev L DECS-100 Installation 4-7

4-8
DECS-100 WITH VOLTAGE MATCHING
FIELD INPUT SENSING VAR/PF PARALLEL EXTERNAL AUX. VOLTAGE
OUTPUT POWER CTB VOLTAGE GROUND BUS CONTROL CONTROL ADJUST ALARM ADJUST MATCHING
F- F+ 3 4 5 CT1 CT2 E3 E2 E1 GND B1 B3 52J 52K 52L 52M 6D 7 6U AL 1 AL 2 A B VM VMC

4 5
10 10

52b S3
S2 S1

A B C
1 2 10 9 10
7
3
10
6
NOTES:
7 1 Required only for optional Var/PF control. Var/PF is active with
8
10
52b open. Var/PF is inactive with 52b closed.
10
2 Parallel control and droop active with S2 open, inactive with S2
closed.
3 S1 (SPDT, spring-return to center-off position) adjusts DECS-100
PMG
10
setpoint.
52
+ 4 Normally-open output contact closes for customer alarm or trip.

DECS-100 Installation
A
10 CTB
GEN B 5 Analog input voltage between +/- 3 Vdc provides adjustment of
11 voltage setpoint.
C
D2881-09 6 External fuses should be Bussman type KTK-10 or equivalent.
05-10-02
Generator Utility
Side Side 7 Sensing potential transformer is required if line voltage exceeds
660 Vac.
8 3-phase PMG is shown. For 1-phase PMG, omit B-phase
connection.
9 Optional voltage matching control input. Voltage matching is
active with S3 closed, inactive with S3 open.
10 Item not supplied by Basler Electric.

11 When generator rotation is ACB, the connections shown for CTB

should be reversed.

Figure 4-6. Typical Connections for PMG Application with ABC Rotation and Three-Phase Sensing

9287500991 Rev L
 DECS-100 WITH VOLTAGE MATCHING
FIELD INPUT SENSING VAR/PF PARALLEL EXTERNAL AUX. VOLTAGE
OUTPUT CTB VOLTAGE GROUND BUS CONTROL CONTROL ADJUST ALARM ADJUST MATCHING
POWER
F- F+ 3 4 5 CT1 CT2 E3 E2 E1 GND B1 B3 52J 52K 52L 52M 6D 7 6U AL 1 AL 2 A B VM VMC

9287500991 Rev L
4 5
10 10

52b S3
S2 S1
A B C
1 2 10 9 10
7
3
10
6 NOTES:
7
8 1 Required only for optional Var/PF control. Var/PF is active with
10 52b open. Var/PF is inactive with 52b closed.
10
2 Parallel control and droop active with S2 open, inactive with S2
closed.

PMG 3 S1 (SPDT, spring-return to center-off position) adjusts DECS-100

10 52 setpoint.
+ 4 Normally-open output contact closes for customer alarm or trip.
A
10 CTB

DECS-100 Installation
GEN B 5 Analog input voltage between +/- 3 Vdc provides adjustment of
voltage setpoint.
C
D2881-11 6 External fuses should be Bussman type KTK-10 or equivalent.
05-10-02
Generator Utility
Side Side 7 Sensing potential transformer is required if line voltage exceeds
660 Vac.
8 3-phase PMG is shown. For 1-phase PMG, omit B-phase
connection.
9 Optional voltage matching control input. Voltage matching is
active with S3 closed, inactive with S3 open.
10 Item not supplied by Basler Electric.

11 When generator rotation is ACB, the connections shown for CTB

should be reversed.

Figure 4-7. Typical Connections for PMG Application with ABC Rotation and Single-Phase Sensing

4-9
4-10
DECS-100 WITH VOLTAGE MATCHING
FIELD INPUT SENSING VAR/PF PARALLEL EXTERNAL AUX. VOLTAGE
OUTPUT CTB VOLTAGE GROUND BUS CONTROL CONTROL ADJUST ALARM ADJUST MATCHING
POWER
F- F+ 3 4 5 CT1 CT2 E3 E2 E1 GND B1 B3 52J 52K 52L 52M 6D 7 6U AL 1 AL 2 A B VM VMC

4 5
10 10

52b S3
S2 S1
A B C
1 2 10 9 10
7
6 3
10
NOTES:
8
1 Required only for optional Var/PF control. Var/PF is active with
7
10 52b open. Var/PF is inactive with 52b closed.
11 10 2 Parallel control and droop active with S2 open, inactive with S2
closed.
3 S1 (SPDT, spring-return to center-off position) adjusts DECS-100
setpoint.
10 52 4 Normally-open output contact closes for customer alarm or trip.
+
A

DECS-100 Installation
10 CTB 5 Analog input voltage between +/- 3 Vdc provides adjustment of
GEN B voltage setpoint.
12
C 6 External fuses should be Bussman type KTK-10 or equivalent.
D2881-10
05-10-02
Generator Utility 7 Sensing potential transformer is required if line voltage exceeds
Side Side 660 Vac.
8 3-phase transformer is shown. For 1-phase transformer, omit B-
phase connection.
9 Optional voltage matching control input. Voltage matching is
active with S3 closed, inactive with S3 open.
10 Item not supplied by Basler Electric.

11 Power potential transformer is required if line voltage exceeds

the specified power input limits.
12 When generator rotation is ACB, the connections shown for CTB
should be reversed.

Figure 4-8. Typical Connections for Shunt Application with ABC Rotation and Three-Phase Sensing

9287500991 Rev L
 DECS-100 WITH VOLTAGE MATCHING
FIELD INPUT SENSING VAR/PF PARALLEL EXTERNAL AUX. VOLTAGE
OUTPUT POWER CTB VOLTAGE GROUND BUS CONTROL CONTROL ADJUST ALARM ADJUST MATCHING
F- F+ 3 4 5 CT1 CT2 E3 E2 E1 GND B1 B3 52J 52K 52L 52M 6D 7 6U AL 1 AL 2 A B VM VMC

9287500991 Rev L
4 5
10 10

52b S3
S2 S1
A B C
1 2 10 9 10
7
6 3
10 NOTES:
8
1 Required only for optional Var/PF control. Var/PF is active with
7
10 52b open. Var/PF is inactive with 52b closed.
11 10
2 Parallel control and droop active with S2 open, inactive with S2
closed.
3 S1 (SPDT, spring-return to center-off position) adjusts DECS-100
setpoint.
10 52 4 Normally-open output contact closes for customer alarm or trip.
+
A
10 CTB 5 Analog input voltage between +/- 3 Vdc provides adjustment of
GEN B voltage setpoint.

DECS-100 Installation
12
C 6 External fuses should be Bussman type KTK-10 or equivalent.
D2659-18
05-10-02
Generator Utility 7 Sensing potential transformer is required if line voltage exceeds
Side Side 660 Vac.
8 3-phase transformer is shown. For 1-phase transformer, omit B-
phase connection.
9 Optional voltage matching control input. Voltage matching is
active with S3 closed, inactive with S3 open.
10 Item not supplied by Basler Electric.

11 Power potential transformer is required if line voltage exceeds

the specified power input limits.
12 When generator rotation is ACB, the connections shown for CTB
should be reversed.

Figure 4-9. Typical Connections for Shunt Application with ABC Rotation and Single-Phase Sensing

4-11
4-12
DECS-100 WITH VOLTAGE MATCHING
FIELD INPUT SENSING VAR/PF PARALLEL EXTERNAL AUX. VOLTAGE
OUTPUT POWER CTB VOLTAGE GROUND BUS CONTROL CONTROL ADJUST ALARM ADJUST MATCHING
F- F+ 3 4 5 CT1 CT2 E3 E2 E1 GND B1 B3 52J 52K 52L 52M 6D 7 6U AL 1 AL 2 A B VM VMC

4 5
10 10

52b S3
S2 S1
6

ICRM-7 8
1 2 10 9 10
7
12 3
10 NOTES:
7 1 Required only for optional Var/PF control. Var/PF is active with
52b open. Var/PF is inactive with 52b closed.
10
STATION 2 Parallel control and droop active with S2 open, inactive with S2
POWER closed.
3 S1 (SPDT, spring-return to center-off position) adjusts DECS-100
setpoint.
10 52
4 Normally-open output contact closes for customer alarm or trip.
+
A

DECS-100 Installation
10 CTB
GEN 5 Analog input voltage between +/- 3 Vdc provides adjustment of
B
11
voltage setpoint.
C 6 External fuses should be Bussman type KTK-10 or equivalent.
P0028-08
03-01-05
Generator Utility
7 Sensing potential transformer is required if line voltage exceeds
Side Side 660 Vac.
8 1-phase power is shown. For 3-phase power, add missing
connection.
9 Optional voltage matching control input. Voltage matching is
active with S3 closed, inactive with S3 open.
10 Item not supplied by Basler Electric.

11 When generator rotation is ACB, the connections shown for CTB

Figure 4-10. Typical Connections for Station Power Application and Three-Phase Sensing
should be reversed.
12 Optional accessory for station power applications.

9287500991 Rev L
 CT
GEN 1

0.1
CTB1

CTB2

DECS-100
CCC LOAD
DECS-100 ENABLE
0.1 CONTACT
CTB1

CTB2

D2880-16
05-19-00
GEN 2
CT

Figure 4-11. Cross-Current (Reactive Differential) Connections

INSTALLATION FOR CE COMPLIANCE

The following paragraphs describe the mounting and wiring requirements for a CE (European
Community) compliant installation.

Mounting
The DECS-100 must be mounted inside a grounded, metal enclosure (conduit box). An access panel
should cover the opening for the front panel display.

Wiring
Wiring connected to the terminals listed below must be shielded. Each shield should be terminated to
ground on the outside of the conduit box.
 Current sensing terminals CT1 and CT2
 Relay output terminals AL1 and AL2
 Var/Power Factor control contact input terminals 52J and 52K
 Parallel generator compensation terminals 52L and 52M
 Raise and lower contact input terminals 6U, 6D, and 7
 Accessory input voltage terminals A and B
 Voltage matching contact input terminals VM and VMC

9287500991 Rev L DECS-100 Installation 4-13

INSTALLATION FOR EMC COMPLIANCE
The following paragraphs describe the mounting and wiring requirements for an EMC (Electromagnetic
Compatibility) compliant installation.

Protection
Internal DECS-100 protection functions must not be used as the primary form of generator protection.

Mounting
The DECS-100 must be mounted inside a grounded, metal, EMC type enclosure (conduit box) with a
grounded, metal access panel which covers the opening for the DECS-100 front panel display.

Wiring
Wiring connected to the terminals listed below must be shielded. Each shield should be terminated to
ground on the outside of the metal enclosure (conduit box).
 Alarm output terminals AL1 and AL2
 External voltage adjust terminals 6D, 7, and 6U
 Var/Power Factor control contact input terminals 52J and 52K
 Parallel generator compensation terminals 52L and 52M
 Field terminals F+ and F-
 AC power input terminals 3, 4, and 5
 Voltage matching contact input terminals VM and VMC

Ferrite Beads
Install one ferrite bead clamp, with the properties listed in Table 4–5, on the wires connected to the
terminals listed in the same row with two turns at the enclosure’s exit or inside the enclosure between 1
and 3 inches (25 and 76 mm) from the connector.

Table 4–5. Ferrite Bead Specifications and Corresponding Wire Terminals

Ferrite
Clamp Impedance Frequency Range Terminals
Grade
AL1, AL2 – Alarm outputs
1 375Ω 31 1 MHz – 300 MHz 6D, 7, 6U – External Voltage Adjust
52J, 52K – Var/Power Factor Control
VM, VMC – Voltage Matching
2 375Ω 31 1 MHz – 300 MHz
52L, 52M – Parallel Gen. Compensation
3 260Ω 31 1 MHz – 300 MHz E1, E2, E3 – Sensing Voltage
4 260Ω 31 1 MHz – 300 MHz 3, 4, 5 – AC Power Input

PRELIMINARY SETUP
Before starting the generator and DECS-100 for the first time, proceed as follows.

WARNING!
Lethal voltage is present at the rear panel when the unit is energized. Rear panel
connections should be made only when the unit is de-energized.

1. Tag and disconnect all wiring to the DECS-100. Be sure to insulate the wire terminals to prevent a
short circuit.
4-14 DECS-100 Installation 9287500991 Rev L
2. Start the prime mover and perform all engine governor adjustments.
3. After all initial governor adjustments have been made, shut down the prime mover.
4. Connect only the DECS-100 power input terminals to an auxiliary power source. Before applying
DECS-100 operating power, observe the precautions noted in Operating Power Considerations
During DECS-100 Programming.
5. Perform all initial DECS-100 settings by connecting a PC operating with BESTCOMS to the rear
communication port of the DECS-100 and save all new settings.
6. Remove power from the DECS-100.
7. Connect the rest of the DECS-100 leads using the tagged identification.
8. Start the prime mover/generator and perform the final adjustments at rated speed and load.
9. After the initial startup, the DECS-100 should not require any further adjustments unless there is a
change in the system.

Operating Power Considerations During DECS-100 Programming

Due to its pulse-width modulated (PWM) power stage, the DECS-100 operating power input has a
substantial amount of capacitance. High inrush current can be experienced upon DECS-100 power-up
when a "solid" power source is used. When powering the DECS-100 for programming with voltage
greater than 120 Vac, high inrush current may damage the unit. Therefore, during programming, DECS-
100 operating power should be within the range of 30 to 120 Vac (50/60 Hz).

CAUTION
When programming the DECS-100 without the generator spinning, the
connections to DECS-100 terminals F+ and F– should be removed.

If it is necessary to perform programming with applied operating power over 120 Vac, a current-limiting
resistor must be connected between the power source and DECS-100 (Figure 4-12). A resistor rated at
20 ohms and 20 watts may be used to limit the inrush current to a safe level. During the duration of the
inrush current (about one cycle), the resistor power rating will be exceeded. Once the inrush has passed,
the resistor power dissipation level will be minimal. If desired, a 10 ohm, 50 watt resistor may be used
instead.

Figure 4-12. Operating Power Connections for DECS-100 Programming (Input Voltage >120 Vac)
These special operating considerations are to be observed only during DECS-100 programming.
Applications where the DECS-100 is powered from the generator output (shunt powered) or a permanent
magnet generator (PMG) are still valid within the constraints given in Section 1, General Information,
Specifications. In applications where station power is used to power the DECS-100, the DECS-100
should be protected by an Inrush Current Reduction Module (ICRM-7). See Power Supply Inputs for more
information.

ADJUSTMENTS
All adjustments are made using external switching, or with BESTCOMS software via the rear panel
communication port. See Sections 5 and 6 for more information regarding setting adjustments with
BESTCOMS software.

9287500991 Rev L DECS-100 Installation 4-15

 This page is intentionally left blank.

4-16 DECS-100 Installation 9287500991 Rev L

SECTION 5  BESTCOMS SOFTWARE
TABLE OF CONTENTS
SECTION 5  BESTCOMS SOFTWARE .................................................................................................. 5-1
INTRODUCTION.................................................................................................................................... 5-1
INSTALLATION...................................................................................................................................... 5-1
Installing BESTCOMS ........................................................................................................................ 5-1
Connecting the DECS-100 and PC .................................................................................................... 5-1
STARTING BESTCOMS........................................................................................................................ 5-1
Establishing Communication .............................................................................................................. 5-2
CHANGING SETTINGS......................................................................................................................... 5-2
SENDING AND RECEIVING SETTINGS .............................................................................................. 5-3
Sending Settings ................................................................................................................................ 5-3
Receiving Settings .............................................................................................................................. 5-3
Saving Settings to DECS-100 Memory .............................................................................................. 5-3
SETTING DEFINITIONS........................................................................................................................ 5-3
System Configuration ......................................................................................................................... 5-3
System Settings .............................................................................................................................. 5-3
Setting Adjustments ........................................................................................................................... 5-4
Setpoint Tab ................................................................................................................................... 5-4
Startup Tab ..................................................................................................................................... 5-5
Control Gain ....................................................................................................................................... 5-6
Control Gain Tab ............................................................................................................................ 5-6
Analysis .............................................................................................................................................. 5-8
AVR Tab ......................................................................................................................................... 5-8
FCR Tab ......................................................................................................................................... 5-9
PF Tab .......................................................................................................................................... 5-11
VAR Tab ....................................................................................................................................... 5-12
Protection Settings ........................................................................................................................... 5-13
Protection Tab .............................................................................................................................. 5-13
Limiter Tab .................................................................................................................................... 5-14
Metering, Operation and Alarms ...................................................................................................... 5-15
Operation Tab ............................................................................................................................... 5-15
Alarm/Status Tab .......................................................................................................................... 5-17
PID DATA............................................................................................................................................. 5-18
PID Calculation Based on Input Values ........................................................................................... 5-18
Adding to the PID List....................................................................................................................... 5-19
Removing a PID List Record ............................................................................................................ 5-19
Retrieving Existing Data from the PID List ....................................................................................... 5-19
SETTINGS FILES ................................................................................................................................ 5-19
Printing Settings Files....................................................................................................................... 5-19
Saving Settings Files ........................................................................................................................ 5-20
Uploading Settings Files................................................................................................................... 5-20
PASSWORD PROTECTION ............................................................................................................... 5-20
Changing the Password ................................................................................................................... 5-20
TERMINATING COMMUNICATION .................................................................................................... 5-21
EMBEDDED FIRMWARE .................................................................................................................... 5-21
Updating the Firmware ..................................................................................................................... 5-21

Figures
Figure 5-1. BESTCOMS Title and Version ................................................................................................ 5-1
Figure 5-2. Communication Port Menu Selection...................................................................................... 5-2
Figure 5-3. Password Dialog Box .............................................................................................................. 5-2
Figure 5-4. Communication Initiation Screen ............................................................................................ 5-2
Figure 5-5. Wait Dialog Box....................................................................................................................... 5-2
Figure 5-6. System Configuration Screen ................................................................................................. 5-4
Figure 5-7. Setting Adjustments Screen, Setpoint Tab ............................................................................. 5-5
Figure 5-8. Setting Adjustments Screen, Startup Tab ............................................................................... 5-6
Figure 5-9. Control Gain Screen................................................................................................................ 5-7
9287500991 Rev L DECS-100 BESTCOMS Software i
Figure 5-10. Analysis Screen, AVR Tab .................................................................................................... 5-9
Figure 5-11. Analysis Screen, FCR Tab .................................................................................................. 5-10
Figure 5-12. Analysis Screen, PF Tab..................................................................................................... 5-11
Figure 5-13. Analysis Screen, VAR Tab .................................................................................................. 5-12
Figure 5-14. Protection Settings, Protection Tab .................................................................................... 5-13
Figure 5-15. Protection Settings Screen, Limiter Tab ............................................................................. 5-14
Figure 5-16. Metering, Operation, and Alarms Screen, Operation Tab .................................................. 5-15
Figure 5-17. Metering, Operation, and Alarms Screen, Alarm/Status Tab.............................................. 5-18
Figure 5-18. PID Window ........................................................................................................................ 5-19
Figure 5-19. Settings Upload Dialog Box ................................................................................................ 5-20
Figure 5-20. Password Dialog Box .......................................................................................................... 5-21
Figure 5-21. Software Uploading Advisory Dialog Box ........................................................................... 5-22
Figure 5-22. DECS-100 Embedded Program Loader ............................................................................. 5-22
Figure 5-23. Retrieved DECS-100 Information ....................................................................................... 5-22
Figure 5-24. Settings File Reminder Dialog Box ..................................................................................... 5-23
Figure 5-25. Open Dialog Box ................................................................................................................. 5-23
Figure 5-26. File Transfer Progress......................................................................................................... 5-23
Figure 5-27. DECS-100 Information After Upload ................................................................................... 5-24

Tables
Table 5-1. DECS-100 Stability Range Settings ......................................................................................... 5-7
Table 5-2. Analysis Screen Tab Combinations ......................................................................................... 5-8

ii DECS-100 BESTCOMS Software 9287500991 Rev L

SECTION 5  BESTCOMS SOFTWARE
INTRODUCTION
BESTCOMS-DECS100 software provides the communication link between the DECS-100 and the user.
All DECS-100 settings are entered through BESTCOMS and all metering values (updated about once
every second) are read through BESTCOMS. Software within BESTCOMS enables the user to establish
proper PID (proportional + integral + derivative) parameters based on a specified generator and/or exciter
time constants. Within BESTCOMS, DECS-100 settings can be saved in a computer file and used later to
configure other units with the same settings.

INSTALLATION
BESTCOMS software for the DECS-100 operates with IBM-compatible personal computers (PCs)
operating with Microsoft® Windows® XP, Vista and 7. The minimum recommended operating
requirements are:
 IBM compatible PC, 486DX2 or faster (100 MHz or higher microprocessor is recommended)
 CD-ROM Drive
 One available serial port

Installing BESTCOMS
BESTCOMS software contains a setup utility that installs the program on your PC. An uninstall utility is
loaded with the program that can be used to remove BESTCOMS from your PC if desired. Use the
following procedure to install BESTCOMS.
1. Insert the CD-ROM into the PC CD-ROM drive.
2. When the DECS-100 Setup and Documentation CD menu appears, click the Install button for the
BESTCOMS PC Program. The setup utility automatically installs BESTCOMS on your PC.
When BESTCOMS is installed, a Basler Electric folder is added to the Windows® program menu. This
folder is accessed by clicking the Start button and pointing to Programs. The Basler Electric folder
contains icons for the BESTCOMS-DECS100 program and a utility to remove BESTCOMS.

Connecting the DECS-100 and PC

Connect a communication cable between the rear RS-232 connector of the DECS-100 and the
appropriate communication port of the PC. Refer to Figure 2-2 for the location of the DECS-100 RS-232
connector and Figure 4-5 for the required connections between the DECS-100 and a PC.

CAUTION
When applying operating power to the DECS-100 for programming purposes,
observe the precautions called out in Section 4, Installation, Preliminary Setup.

STARTING BESTCOMS
BESTCOMS is started by clicking the Windows® Start
button, pointing to Programs, the Basler Electric folder,
and then clicking the BESTCOMS-DECS100 icon. At
startup, a dialog box with the program title and version
number is displayed briefly (Figure 5-1). After this dialog
box is displayed, the System Configuration screen is
displayed.

Figure 5-1. BESTCOMS Title and Version

9287500991 Rev L DECS-100 BESTCOMS Software 5-1

Establishing Communication
Communication between BESTCOMS and the
DECS-100 must be established before viewing
metering values or reading or changing settings.
BESTCOMS screen settings are updated only
after communication is opened or the
communication settings have been changed.
Open the DECS-100 communication port by
clicking on Communications on the menu bar,
hovering the mouse pointer over Open Comm
Figure 5-2. Communication Port Menu Selection
Port, and clicking RS-232 Port. Figure 5-2
illustrates the menu selections for opening the
DECS-100 communication port.
When RS-232 Port is selected, the Password dialog box of Figure 5-3 appears and prompts you to enter
a password. Each DECS-100 is delivered with "decs" as the default password. See the Password
Protection sub-section for information about changing the password.
After the correct password is entered, the Communication Initiation screen of Figure 5-4 is displayed.
Select Comm 1, Comm 2, Comm 3, or Comm 4 as the active communication port on your PC and click
the Initialize button. BESTCOMS initializes communication by obtaining the configuration settings from
the DECS-100.

NOTE
BESTCOMS may display the dialog box of
Figure 5-5 when initializing DECS-100 commu-
nication, obtaining DECS-100 configuration set-
tings, or performing other tasks. It's important to
Figure 5-3. Password Dialog Box wait until the box disappears before trying to
execute communication commands. Issuing
commands while the Wait dialog box is present
may disrupt communication between the DECS-
100 and BESTCOMS.

Figure 5-5. Wait Dialog Box

Figure 5-4. Communication Initiation Screen

CHANGING SETTINGS
Settings are arranged into six groups.
 System Configuration  Analysis
 Setting Adjustments  Protection/Relay
 Control Gain  Metering/Operation
Each setting group has a corresponding toolbar button that can be selected to access that group of
settings. The six setting groups can also be accessed by clicking Screens on the menu bar and then
selecting the desired setting group from the list. Once a setting group is accessed, the individual settings
of the group can be viewed and changed.
A setting is changed by clicking within the setting field and typing the new setting. The range limits of a
setting can be viewed by double-clicking the setting. Once all desired setting changes have been made
on a setting group screen, the settings must be sent to the DECS-100 before viewing other screens.
Otherwise, the settings changes will be lost. Settings changes can be sent to the DECS-100 by clicking
the SendToDECS button. Settings can also be sent to the DECS-100 by clicking Communications on
the menu bar and clicking Send To DECS.

5-2 DECS-100 BESTCOMS Software 9287500991 Rev L

SENDING AND RECEIVING SETTINGS
When communication is enabled, DECS-100 settings can be sent or received through BESTCOMS.

Sending Settings
Settings changes are sent to the DECS-100 by clicking the SendToDECS button. This causes the
selected setting displayed on the current settings screen to become the DECS-100 setting. Settings can
also be sent to the DECS-100 by clicking Communications on the menu bar and clicking Send To
DECS. Additionally, a setting can be sent by pressing the Enter key after the new value is typed in. The
SendToDECS button must be clicked or the Enter key must be pressed after each setting change to
ensure that all settings are sent to the DECS-100. See Saving Settings to DECS-100 Memory for
information about retaining DECS-100 settings after operating power is removed.

Receiving Settings
DECS-100 settings are retrieved by clicking the GetFromDECS button. This causes the current settings
of the DECS-100 to be displayed on the settings screen. Settings can also be received from the DECS-
100 by clicking Communications on the menu bar and clicking Get From DECS.

Saving Settings to DECS-100 Memory

Settings are saved in nonvolatile memory (EEPROM). In the event of a power loss, these are the settings
that are active at power up. If settings are changed and sent to the DECS-100, but not sent to EEPROM,
the changed settings are lost if DECS-100 operating power is lost. When exiting BESTCOMS or closing
communication, you are asked if you want to save the settings to EEPROM. This question is asked even
if no settings changes were made.
When communication is enabled, setting changes are saved to EEPROM by clicking the EEPROM
button. The opportunity to save settings to EEPROM is also given through a dialog box when exiting
BESTCOMS or closing communication.

SETTING DEFINITIONS
Each of the six setting groups has a corresponding BESTCOMS screen. The settings of each screen are
categorized by one or more tabs. In the following paragraphs, settings are arranged and defined
according to the organization of the BESTCOMS screens and tabs.

System Configuration
The System Configuration screen consists of one tab labeled System Settings. Click the Configure
button to access the System Configuration screen or click Screens on the menu bar and click System
Configuration.
System Settings
System settings are shown in Figure 5-6 and described in the following paragraphs.
Sensing Voltage. This setting is used to configure the DECS-100 for either single-phase or three-phase
sensing voltage.
Limiter Mode. This setting enables and disables the excitation limiters. Overexcitation limiting (OEL) or
underexcitation limiting (UEL) can be enabled independently, both can be enabled, or neither limiter
enabled.
OEL Type. This setting configures the overexcitation limiter as a summing point limiter or takeover-style
limiter.
Generator Frequency. This setting is used to select a nominal system operating frequency of 50 hertz or
60 hertz.
Setpoint Auto Save. When enabled, this feature automatically saves setpoint changes in nonvolatile
memory. A change made to any setpoint (AVR, FCR, Var, or PF) initiates a 10 minute time delay. When
the time delay expires, the DECS-100 automatically saves the setpoint values in nonvolatile memory.
When disabled, this feature is not active and any setpoint changes must be saved to nonvolatile memory
by clicking the EEPROM button.

9287500991 Rev L DECS-100 BESTCOMS Software 5-3

Regulator Sensing Voltage (V). The nominal, ac generator voltage obtained from the generator sensing
transformer is entered in this setting field. Voltages within the ranges of 100 to 140 Vac, 200 to 280 Vac,
or 400 to 560 Vac may be entered in 0.1 Vac increments. A setting of 600 Vac is also possible.
Regulator Sensing Current (A). This setting field reads and displays the nominal output of the current
transformer (CT) that supplies the DECS-100 with B-phase generator line current. This value (1 or 5)
must be manually entered for units with a firmware version lower than 1.12.01.

Figure 5-6. System Configuration Screen

Version Numbers. These two read-only version numbers indicate the BESTCOMS software version and
the DECS-100 embedded software version. Version numbers are displayed only when communication
between the DECS-100 and BESTCOMS is established.

Style Number. The three, read-only style number fields indicate the electrical characteristics and
operational features of the DECS-100. the style number is displayed only when communication between
the DECS-100 and BESTCOMS is established.
Generator PT Ratio. The ratio of the generator sensing transformer is entered in this setting field. This
ratio allows the voltage displayed through BESTCOMS to match the actual generator output voltage. A
ratio of 1 to 150 may be entered in increments of 0.01.
Generator CT Ratio. The ratio of the generator B-phase current transformer is entered in this setting field.
This ratio allows the current displayed by the DECS-100 to match the actual B-phase generator output
current. A ratio of 1 to 3,000 may be entered in increments of 0.1.
Bus PT Ratio. This setting field is used to enter the bus potential sensing transformer ratio. This ratio
allows the bus voltage to be displayed through BESTCOMS. A ratio of 1 to 150 may be entered in 0.01
increments.

Setting Adjustments
The Setting Adjustments screen consists of two tabs: Setpoint and Startup.
Setpoint Tab
The Setpoint tab settings of the Setting Adjustments screen are shown in Figure 5-7. Each setting of the
Setpoint tab is described in the following paragraphs.
Automatic Voltage Regulator (AVR) - AVR Setpoint (V). This setting field is used to enter the desired
generator output terminal voltage. The AVR setpoint value range depends on the regulator sensing
voltage and band setting.

5-4 DECS-100 BESTCOMS Software 9287500991 Rev L

Fine Voltage Adjustment - Band Setting (%). The Band Setting determines the minimum and maximum
adjustment allowed to the AVR Setpoint (as a percentage of the Regulator Sensing Voltage setting (see
Figure 5-8)). Band Setting values are entered as a percentage of the regulator sensing voltage setting
over a range of 0 to 15%in 0.1% increments.
Droop - Setpoint (%). This setting controls the reactive droop compensation feature of the DECS-100.
The setpoint value determines the amount of change permitted in the generator voltage setpoint when the
DECS-100 responds to a reactive load. The setpoint value is adjustable from 0 to 10% in increments of
0.01%. The setpoint is based on a 0.8 power factor load.
Field Current Regulator (FCR) - FCR Setpoint (A). This setting defines the field current setpoint when
operating in Manual mode. The FCR Setpoint field accepts a value of 0 to 7 Adc in 0.01 Adc increments.

Figure 5-7. Setting Adjustments Screen, Setpoint Tab

Reactive Power Control (VAR) - VAR Setpoint (% of rated). The VAR Setpoint determines the level of
generator vars maintained by the DECS-100 when operating in Var Control mode. Values from -100 to
+100 percent in 1.0 percent increments may be entered in the VAR Setpoint field.
Power Factor Control (PF) - PF Setpoint. The PF Setpoint determines the level of generator power factor
maintained by the DECS-100 when operating in Power Factor Control mode. PF Setpoint values are
adjustable from -0.6 to -1 (1) or 0.6 to +1 in 0.001 increments.
Startup Tab
The Startup-tab settings of the Setting Adjustment screen are shown in Figure 5-8. Each setting of the
Startup tab is described in the following paragraphs.
Startup Control - Gen Soft Start Time (sec). This setting defines the time limit for the generator soft-start
voltage ramp time. The soft-start time minimizes generator voltage overshoot and can be set from 1 to
7,200 seconds in 1 second increments.
Underfrequency Setting - Corner Frequency (Hz). The Corner Frequency setting defines the value of
frequency that causes the DECS-100 to adjust the voltage setpoint so that the generator voltage follows
the selected volts per hertz slope. A value of 40 to 65 hertz can be entered in this setting field in 0.01
increments.
Underfrequency Setting - Slope (Volts/Hz). The slope for generator underfrequency protection is selected
with this per-unit setting. A slope setting of 0 to 3.00 can be entered in increments of 0.01.
Voltage Matching - Speed (sec). This setting determines how quickly the generator voltage is adjusted by
the DECS-100 to match the bus voltage. The Speed setting is adjustable from 1 to 300 seconds in 0.01
increments.
9287500991 Rev L DECS-100 BESTCOMS Software 5-5
Voltage Matching – Disable by Contact. This setting selects the DECS-100 contact input used to disable
voltage matching. Selecting “52JK or 52LM” allows either the 52JK or 52LM contact input to disable
voltage matching. Selecting “52JK” allows only the 52JK contact input to disable voltage matching.
Voltage Matching – Mode. The voltage matching mode can be Maintain or Revert. When Maintain is
selected, the DECS-100 setpoint is maintained at the bus voltage level even after the generator or utility
breaker opens. When Revert is selected, the DECS-100 setpoint reverts to its original level when the
generator or utility breaker opens.

Figure 5-8. Setting Adjustments Screen, Startup Tab

Control Gain
The Control Gain screen consists of one tab labeled Control Gain. Click the Gain button to access the
Control Gain screen or click Screens on the menu bar and click Control Gain.
Control Gain Tab
Control gain settings are shown in Figure 5-9 and are described in the following paragraphs.
Stability Range. This setting selects one of 20 preset stability ranges within the DECS-100. A guide for
selecting the stability range is provided in Table 5-1. A setting of 21 enables the entry of custom stability
settings through the BESTCOMS PID window. Information about the PID window is provided later under
the heading of PID Window. When the Stability Range is set at 21, the PID button may be selected to
access the PID window. A Stability Range setting of 1 through 20 disables the PID button and prevents
access to the PID window.
AVR/FCR - Proportional Gain KP. This setting selects the proportional constant (KP) stability parameter.
The DECS-100 supplies a value that is equivalent to KP multiplied by the error between the voltage
setpoint and the actual generator output voltage. KP values of 0 to 1,000 may be entered in increments of
0.01.
Observe the following guidelines when tuning the KP value. If the transient response has too much
overshoot, then KP should be decreased. If the transient response is too slow, then KP should be
increased.

5-6 DECS-100 BESTCOMS Software 9287500991 Rev L

 Figure 5-9. Control Gain Screen

Table 5-1. DECS-100 Stability Range Settings

Generator Time Constants Stability
Size Generator (T’do) Exciter (Texc) Range
SMALL 1.0 0.17 1
1.5 0.25 2
2.0 0.33 3
2.5 0.42 4
3.0 0.50 5
3.5 0.58 6
4.0 0.67 7
4.5 0.75 8
5.0 0.83 9
5.5 0.92 10
6.0 1.00 11
6.5 1.08 12
7.0 1.17 13
7.5 1.25 14
8.0 1.33 15
8.5 1.42 16
9.0 1.50 17
9.5 1.58 18
10.0 1.67 19
LARGE 10.5 1.75 20

AVR/FCR - Integral Gain KI. This setting selects the integral constant (KI) stability parameter. The DECS-
100 supplies a value that is equivalent to KI multiplied by the integral of the error between the voltage
setpoint and the actual generator output voltage. KI values of 0.01 to 1,000 may be entered in increments
of 0.01.
Increasing the value of KI decreases the time required to reach steady state.
9287500991 Rev L DECS-100 BESTCOMS Software 5-7
AVR/FCR - Derivative Gain KD. This setting selects the derivative constant (KD) stability parameter. The
DECS-100 provides an output value that is equivalent to KD multiplied by the derivative of the error
between the voltage setpoint and the actual generator output voltage. KD values of 0 to 1,000 may be
entered in increments of 0.01.
Increasing the value of KD reduces transient response ringing.
AVR/FCR - AVR<=Loop Gain Kg=>FCR. This setting adjusts the loop-gain level of the PID algorithm.
Loop Gain values of 0 to 1,000 may be entered for AVR and FCR operation in increments of 0.01.
VAR/PF - PF Integral Gain KI. This setting adjusts the integral gain and determines the characteristic of
the DECS-100 dynamic response to a changed PF setting. PF KI values of 0 to 1,000 may be entered in
increments of 0.01.
VAR/PF - Var Integral Gain KI. This setting adjusts the integral gain and determines the characteristic of
the DECS-100 dynamic response to a changed var setting. Var KI values of 0 to 1,000 may be entered in
increments of 0.01.
VAR/PF - VAR<=Loop Gain Kg=>PF. This setting adjusts the loop-gain level of the PI algorithm for var or
power factor control. Loop Gain values of 0 to 1,000 may be entered for var and power factor operation in
increments of 0.01.
OEL/UEL – OEL Integral Gain KI. This setting controls the rate at which the DECS-100 responds during
an overexcitation event. KI values of 0 to 300 may be entered in increments of 0.01.
OEL/UEL – OEL Loop Gain Kg. This setting adjusts the coarse loop-gain level of the PID algorithm for the
overexcitation limiting function. Loop Gain values of 0 to 300 may be entered in increments of 0.01.
OEL/UEL – UEL Integral Gain KI. This setting controls the rate at which the DECS-100 responds during
an underexcitation event. KI values of 0 to 300 may be entered in increments of 0.01.
OEL/UEL – UEL Loop Gain Kg. This setting adjusts the coarse loop-gain level of the PID algorithm for the
underexcitation limiting function. Loop Gain values of 0 to 300 may be entered in increments of 0.01.

Analysis
Click the Analysis button or click Screens on the Menu bar and click Analysis to view the Analysis
screen. The Analysis screen consists of four tabs: VAR, PF, AVR, and FCR. Each of the tabs displays
four metered sensing values and has six alarm signal indicators. Metered sensing values include Vrms
(rms voltage), Ifd (dc field current), reactive power (vars), and power factor (PF). Alarm signal indicators
include Overexcitation Limiting, Underexcitation Limiting, Generator Overvoltage, Loss of Generator
Sensing, Underfrequency Active, and Overexcitation Shutdown.
The operating status and control mode of the DECS-100 determine which tabs of the Analysis screen are
enabled and can be accessed by the user. Table 5-2 lists the DECS-100 operating status and control
modes that enable the four tabs of the Analysis screen.
Table 5-2. Analysis Screen Tab Combinations
Control Mode Operating Status Tab Enabled
AVR OFF AVR
AVR PF AVR, PF
AVR VAR AVR, VAR
FCR N/A FCR

Control mode and operating status selections are made at the Operation tab of the BESTCOMS Metering
screen and are discussed later in this section.
AVR Tab
Figure 5-10 illustrates the settings, sensing values, and alarm signal indicators of the AVR tab. The
settings of the AVR tab make it possible to increment and decrement the AVR setpoint of the DECS-
100.The sensing values and alarm signal indicators of the AVR tab are also displayed by the other tabs of
the Analysis screen.
Voltage Step Response - AVR Setpoint (V) (Nominal). This read-only field indicates the AVR setpoint.
(The AVR setpoint is set by using the Setpoint tab of the Setting Adjustments screen). The voltage
displayed in the AVR Setpoint field is selected by clicking the adjacent button. Clicking this button sends
the AVR Setpoint value to the DECS-100 and changes the color of the button from gray to red.
5-8 DECS-100 BESTCOMS Software 9287500991 Rev L
Voltage Step Response - Increment of AVR Setpoint (V). These two fields indicate the increase that
occurs to the AVR setpoint when the corresponding Increment button is clicked. The "% increase" field is
used to set and indicate the percentage that the AVR setpoint is increased when the Increment button is
clicked. The "AVR Setpoint =" field indicates the value of voltage that corresponds to the "% increase"
field. Any setpoint value within range or higher than the setpoint value can be typed into the "AVR
Setpoint ="field, which updates the "% increase" field. The AVR setpoint changes to this value when the
adjacent button is clicked. When clicked, the Increment button changes from gray to red to indicate that
the AVR setpoint has increased to the value in the "AVR Setpoint =" field.

Figure 5-10. Analysis Screen, AVR Tab

Voltage Step Response - Decrement of AVR Setpoint (V). These two fields indicate the change that will
occur to the AVR setpoint when the corresponding Decrement button is clicked. The "% decrease" field is
used to set and indicate the percentage (0 to 10%) that the AVR setpoint is decreased when the
Decrement button is clicked. The "AVR Setpoint =" field indicates the value of voltage that corresponds to
the "% decrease" field. Any setpoint value within range or lower than the setpoint value can be typed into
the "AVR Setpoint =" field, which updates the "% decrease" field. The AVR setpoint changes to this value
when the adjacent button is clicked. When clicked, the Decrement button changes from gray to red to
indicate that the AVR setpoint has decreased to the value in the "AVR Setpoint =" field.
Voltage Step Response - Meter Value. This field and the dial pointer indicate the value of the selected
AVR setpoint. When the AVR setpoint is changed by clicking the increment, decrement, or setpoint
button, the meter value field and dial pointer indicate the new setpoint value. A new AVR setpoint can be
typed directly into the Meter Value field or selected by dragging the dial pointer to the desired value. The
new value is sent to the DECS-100 by clicking the Send button.
Voltage Step Response - Current Setpoint. The active DECS-100 setpoint (adjusted by using any of the
previously mentioned methods) is displayed in this field. To return the AVR setpoint to the nominal
setting, the button adjacent to the "AVR Setpoint (V) (Nominal)" field should be clicked. If the AVR tab is
left to view other tabs or screens without returning the AVR setpoint to nominal, an AVR dialog box
appears. Clicking the Yes button returns the AVR setpoint to nominal. Clicking No maintains the AVR
setpoint at the current value.
FCR Tab
Figure 5-11 illustrates the settings, sensing values, and alarm signal indicators of the FCR tab. The
settings of the FCR tab make it possible to increment and decrement the FCR setpoint of the DECS-100.
The sensing values and alarm signal indicators of the FCR tab are also displayed by the other tabs of the
Analysis screen.

9287500991 Rev L DECS-100 BESTCOMS Software 5-9

Field Current Step Response - FCR Setpoint (A). This read-only field indicates the FCR setpoint. (The
FCR setpoint is set by using the Setpoint tab of the Setting Adjustments screen). The current displayed in
the FCR Setpoint field is selected by clicking the adjacent pushbutton. Clicking this button sends the FCR
Setpoint value to the DECS-100 and changes the color of the pushbutton from gray to red.
Field Current Step Response - Increment of FCR Setpoint (A). These two fields indicate the increase that
occurs to the FCR setpoint when the corresponding Increment button is clicked. The "% increase" field is
used to set and indicate the percentage (0 to 10%) that the FCR setpoint is increased when the
Increment button is clicked. The "FCR Setpoint =" field indicates the value of current that corresponds to
the "% increase" field. Any setpoint value within range or higher than the setpoint value can be typed into
the "FCR Setpoint =" field, which updates the "% increase" field. The FCR setpoint changes to this value
when the adjacent button is clicked. When clicked, the Increment button changes from gray to red to
indicate that the FCR setpoint has increased to the value in the "FCR Setpoint =" field.

Figure 5-11. Analysis Screen, FCR Tab

Field Current Step Response - Decrement of FCR Setpoint (A). These two fields indicate the change that
will occur to the FCR setpoint when the corresponding Decrement button is clicked. The "% decrease"
field is used to set and indicate the percentage that the FCR setpoint is decreased when the Decrement
button is clicked. The "FCR Setpoint =" field indicates the value of current that corresponds to the "%
decrease" field. The FCR setpoint changes to this value when the adjacent button is clicked. When
clicked, the Decrement button changes from gray to red to indicate that the FCR setpoint has decreased
to the value in the "FCR Setpoint =" field.
Field Current Step Response - Meter Value. This field and the dial pointer indicate the value of the
selected FCR setpoint. When the AVR setpoint is changed by clicking the increment, decrement, or
setpoint button, the meter value field and dial pointer indicate the new setpoint value. A new FCR setpoint
can be typed directly into the "Meter Value" field or selected by dragging the dial pointer to the desired
value. The new value is sent to the DECS-100 by clicking the Send button.
Field Current Step Response - Current Setpoint. The active DECS-100 setpoint (adjusted by using any of
the previously mentioned methods) is displayed in this field. To return the FCR setpoint to the nominal
setting, the button adjacent to the "FCR Setpoint (A) (Nominal)" field should be clicked. If the FCR tab is
left to view other tabs or screens without returning the FCR setpoint to nominal, an FCR setpoint dialog
box appears. Clicking the Yes button returns the AVR setpoint to nominal. Clicking No maintains the AVR
setpoint at the current level.

5-10 DECS-100 BESTCOMS Software 9287500991 Rev L

PF Tab
Figure 5-12 illustrates the settings, sensing values, and alarm signal indicators of the PF tab. Each setting
of the PF tab is described in the following paragraphs.
Power Factor Step Response - Power Factor Setpoint (Nominal). This read-only field indicates the PF
setpoint. (The PF setpoint is set by using the Setpoint tab of the Setting Adjustments screen.) The value
displayed in the FCR Setpoint field is selected by clicking the adjacent pushbutton. Clicking this button
sends the PF setpoint value to the DECS-100 and changes the color of the pushbutton from gray to red.
Power Factor Step Response - Increment of PF Setpoint. This field indicates the new PF setpoint that is
established when the corresponding increment button is clicked. Any setpoint value within range or higher
than the existing setpoint value can be typed into the "Increase PF Setpoint =" field. The PF setpoint
changes to this value when the adjacent button is clicked. When clicked, the Increment button changes
from gray to red to indicate that the PF setpoint has increased to the value in the "Increase PF Setpoint ="
field.

Figure 5-12. Analysis Screen, PF Tab

Power Factor Step Response - Decrement of PF Setpoint. This field indicates the new PF setpoint that is
established when the corresponding decrement button is clicked. Any setpoint value within range or lower
than the existing setpoint value can be typed into the "Decrease PF Setpoint =" field. The PF setpoint
changes to this value when the adjacent button is clicked. When clicked, the Decrement button changes
from gray to red to indicate that the PF setpoint has decreased to the value in the "Decrease PF Setpoint
=" field.
Power Factor Step Response - PF Value. This field and the dial pointer indicate the value of the selected
PF setpoint. When the PF setpoint is changed by clicking the increment, decrement, or setpoint button,
the meter value field and dial pointer indicate the new setpoint value. A new PF setpoint can be typed
directly into the "PF Value" field or selected by dragging the dial pointer to the desired value. The new
value is sent to the DECS-100 by clicking the Send button.
Power Factor Step Response - Current Setpoint. The active DECS-100 setpoint (adjusted by using any of
the previously mentioned methods) is displayed in this field. To return the PF setpoint to the nominal
setting, the button adjacent to the PF Setpoint (Nominal) field should be clicked. If the PF tab is left to
view other tabs or screens without returning the PF setpoint to nominal, a PF setpoint dialog box appears.
Clicking the Yes button returns the AVR setpoint to nominal. Clicking No maintains the AVR setpoint at
the current value.

9287500991 Rev L DECS-100 BESTCOMS Software 5-11

VAR Tab
Figure 5-13 illustrates the settings, sensing values, and alarm signal indicators of the VAR tab. Each
setting of the VAR tab is described in the following paragraphs.
Reactive Power Step Response - VAR Setpoint (%) (Nominal). This read-only field indicates the var
setpoint. (The var setpoint is set by using the Setpoint tab of the Setting Adjustments screen.) The value
displayed in the "VAR Setpoint" field is selected by clicking the adjacent button. Clicking this button sends
the var setpoint value to the DECS-100 and changes the color of the pushbutton from gray to red.
Reactive Power Step Response - Increment of VAR Setpoint (%). This field indicates the increase that
occurs to the FCR setpoint when the corresponding Increment button is clicked. The "Increase VAR
Setpoint =" field is used to set and indicate the percentage that the var setpoint is increased to when the
Increment button is clicked. Any setpoint value (expressed as a percent of nominal) within range or higher
than the existing setpoint value can be typed into the "Increase VAR Setpoint =" field. The var setpoint
changes to the new value when the adjacent button is clicked. Clicking this button sends the var setpoint
value to the DECS-100 and changes the color of the pushbutton from gray to red.

Figure 5-13. Analysis Screen, VAR Tab

Reactive Power Step Response - Decrement of VAR Setpoint (%). This field indicates the decrease that
occurs to the FCR setpoint when the corresponding Decrement button is clicked. The "Decrease VAR
Setpoint =" field is used to set and indicate the percentage that the var setpoint is decreased to when the
Decrement button is clicked. Any setpoint value (expressed as a percent of nominal) within range or lower
than the existing setpoint value can be typed into the "Decrease VAR Setpoint =" field. The var setpoint
changes to the new value when the adjacent button is clicked. Clicking this button sends the var setpoint
value to the DECS-100 and changes the color of the pushbutton from gray to red.
Reactive Power Step Response - Meter Value. These fields and the dial pointer indicate the value of the
selected var setpoint. When the var setpoint is changed by clicking the increment, decrement, or setpoint
button, the meter value fields and dial pointer indicate the setpoint value. A new var setpoint, expressed
as a kvar value or a percentage of nominal, can be typed directly into either Meter Value field or selected
by dragging the dial pointer to the desired value. The new value is sent to the DECS-100 by clicking the
Send button.
Reactive Power Step Response - Current Setpoint (%). The active var setpoint (adjusted by using any of
the previously mentioned methods) is displayed in this field. To return the var setpoint to the nominal
setting, the button adjacent to the "VAR Setpoint (%) (Nominal)" field should be clicked. If the VAR tab is
left to view other tabs or screens without returning the VAR setpoint to nominal, a var setpoint dialog box
appears. Clicking the Yes button returns the var setpoint to nominal. Clicking No maintains the var
setpoint at the current value.
5-12 DECS-100 BESTCOMS Software 9287500991 Rev L
Protection Settings
The Protection Settings screen consists of two tabs: Protection and Limiter. Click the Protection button to
access the Protection Settings screen or click Screens on the menu bar and click Protection Settings.
Protection Tab
Protection settings are shown in Figure 5-14 and are described in the following paragraphs.
Generator Overvoltage - Voltage Level (%). The value of this field is expressed as a percentage of the
nominal generator voltage and determines the level of generator voltage required to initiate a generator
overvoltage condition. An overvoltage percentage value of 100 to 120 percent may be entered in 1
percent increments. A generator overvoltage condition lights the Generator Overvoltage LED on the front
panel.
Generator Overvoltage – Alarm Time Delay (sec). This setting establishes the length of time that a
generator overvoltage condition must exist before the DECS-100 annunciates the condition.

Figure 5-14. Protection Settings, Protection Tab

Generator Overvoltage - Hardware Shutdown. Enabling Hardware Shutdown will cause the DECS-100 to
remove field excitation when the generator overvoltage setting is exceeded. Disabling Hardware
Shutdown prevents the DECS-100 from removing excitation during a generator overvoltage condition.
Generator Overvoltage – Alarm. This setting enables and disables closure of the DECS-100 Alarm output
(terminals AL1 and AL2) during generator overvoltage. Disabling the alarm also disables hardware
shutdown.
Field Overvoltage - Voltage Level (Vdc). The value in this field is adjustable from 0 to 250 Vdc and
determines the field voltage level that will cause the DECS-100 to issue an overexcitation limit alarm.
When the field voltage increases above the value of this field for 10 seconds, the Overexcitation
Shutdown LED on the front panel lights.
Field Overvoltage - Alarm. If the Alarm is enabled and a field overvoltage condition exists for 10 seconds,
the DECS-100 Alarm output (terminals AL1, AL2) will close. Disabling the Alarm prevents the Alarm
output from closing when a field overvoltage condition exists. Disabling the alarm also disables hardware
shutdown.
Field Overvoltage - Hardware Shutdown. When Hardware Shutdown is enabled, the DECS-100 will
remove field excitation when a field overvoltage condition exists for 10 seconds.
Loss of Sensing Voltage - LOS Option. One of two DECS-100 responses can be selected for a loss of
sensing voltage condition. Selecting Shutdown Regulator will cause the DECS-100 to remove field
excitation when loss of sensing voltage occurs. Selecting Transfer To FCR will cause the DECS-100 to
transfer to FCR mode when a loss of sensing voltage occurs.
9287500991 Rev L DECS-100 BESTCOMS Software 5-13
Loss of Sensing Voltage - Time Delay (sec). The value of this field determines the time delay between
when a loss of sensing voltage is recognized and the DECS-100 responds according to the Hardware
Shutdown and LOS Option options selected. A time delay of 0 to 25 seconds may be entered in 1 second
increments.
Loss of Sensing Voltage - Hardware Shutdown. Enabling Hardware Shutdown will cause the DECS-100
to remove field excitation when a loss of sensing voltage occurs. Disabling Hardware Shutdown prevents
the DECS-100 from removing excitation during a loss of sensing voltage.
Limiter Tab
Limiter tab settings are shown in Figure 5-15 and described in the following paragraphs.
OEL - Current Level (A). The value of current in this field determines the excitation level that will cause
the DECS-100 to issue an overexcitation limit alarm. A current level of 0 to 15 A may be entered in 0.01
increments. When the level of field current increases above the value of this field, the Overexcitation
Shutdown LED on the front panel lights and the OEL time delay starts timing down.

Figure 5-15. Protection Settings Screen, Limiter Tab

OEL - Alarm Time Delay (sec). The value of this field determines the time delay between when the
DECS-100 recognizes an overexcitation condition and the DECS-100 Alarm output (terminals AL1, AL2)
closes. A time delay of 0 to 10 seconds may be entered in 1 second increments.
OEL - Hardware Shutdown. If the hardware shutdown feature is enabled and an overexcitation condition
exists for the duration of the Alarm Time Delay, the DECS-100 will stop excitation when the Alarm output
closes.
UEL – VAR Level (%). This setting, expressed as a percentage of the leading var setpoint, determines the
excitation level that will cause the DECS-100 to issue an underexcitation limit alarm. A setting of 0 to
100% may be entered in 1% increments. When the var level decreases below this setting, the
Underexcitation Limiting LED on the front panel lights and the UEL time delay starts timing down.
UEL – Alarm Time Delay (sec). The value of this field determines the time delay between when the
DECS-100 recognizes an underexcitation condition and the DECS-100 Alarm output (terminals AL1, AL2)
closes. A time delay of 0 to 10 seconds may be entered in 1 second increments.
UEL – Hardware Shutdown. If the hardware shutdown feature is enabled and an underexcitation
condition exists for the duration of the Alarm Time Delay, the DECS-100 will stop excitation when the
Alarm output closes.

5-14 DECS-100 BESTCOMS Software 9287500991 Rev L

Metering, Operation and Alarms
The Metering, Operation and Alarms screen is viewed by clicking the Metering button or by clicking
Screens on the Menu bar and clicking Metering/Operation. Information displayed on the Metering,
Operation and Alarms screen can be frozen by clicking the Metering button while viewing the screen or by
clicking Metering on the Menu bar and clicking Disable Metering. Metering can be resumed by clicking the
Metering button or by clicking Metering on the Menu bar and clicking Enable Metering. The Metering,
Operation and Alarms screen consists of two tabs: Operation and Alarm/Status.
Operation Tab
Operation tab metering values, setpoint values, and control functions are illustrated in Figure 5-16.
Gen Voltage (V). These metering values report the status of the VA-B, VC-B, VC-A, and VAVG generator
voltages. The reported values are the product of the voltage sensed at terminals E1, E2, and E3 and the
generator PT ratio. All metering values are updated once each second. When single-phase sensing is
used (System Configuration screen, Sensing Voltage) and the DECS-100 sensing voltage terminals (E1,
E2, and E3) are connected as shown in Figures 4-7 or 4-9, all of the generator voltage metering values
will be identical.

Figure 5-16. Metering, Operation, and Alarms Screen, Operation Tab

Gen Current (A). This metering value indicates the level of the B-phase generator current. This value is
the product of the current input to CT1 and CT2 and the CT ratio. Generator current is monitored through
DECS-100 terminals CT1 and CT2.
Gen Frequency (Hz). This metering value indicates the frequency of the monitored generator voltage.
Power - VA. This metering value indicates apparent power and is the calculated product of the metered
generator voltage (VAVG), PT ratio (entered at the System Configuration screen), metered generator
current (Ib), CT ratio (entered at the System Configuration screen), and the square root of 3. See
Equation 5-1.

VA  V AVG  I B  3
Equation 5-1
Power – W. This metering value indicates real power and is the calculated product of the metered
generator voltage(VAVG), PT ratio (entered at the System Configuration screen), metered generator
current (Ib) CT ratio (entered at the System Configuration screen), square root of 3, and the cosine of the
metered phase angle. See Equation 5-2.

9287500991 Rev L DECS-100 BESTCOMS Software 5-15

 W  V AVG  I B  3  cos 
Equation 5-2
Power – Var. This metering value indicates reactive power and is the calculated product of the metered
generator voltage(VAVG), PT ratio (entered at the System Configuration screen), metered generator
current (Ib) CT ratio (entered at the System Configuration screen), square root of 3, and the sine of the
metered phase angle. See Equation 5-3.

var  V AVG  I B  3  sin 

Equation 5-3
Power – PF. This metering value indicates the power factor and is the calculated result of dividing the
Real Power (W) value by the Apparent Power (VA) value. See Equation 5-4.
PF  W  VA
Equation 5-4
Phase Angle (Degree). This metering value indicates the phase angle difference (in degrees) between the
generator voltage and the generator current.
Aux DC Input (V). This metering value indicates the level of dc control voltage applied from a remote
device to DECS-100 terminals A and B. The displayed value correlates to the generator voltage setpoint.
Bus Voltage (V). This metering value indicates the amount of bus voltage present at the utility side of the
tie circuit breaker. The displayed value is the product of the voltage sensed at terminals B1 and B3 and
the bus PT ratio.
Field Voltage (V). This metering value indicates the value of voltage being supplied from the DECS-100
output (terminals F+ and F-) to the generator field.
Field Current (A). This metering value indicates the amount of current flowing from the DECS-100 output
(terminals F+ and F-) to the generator field.
Regulator Output (%). This metering value indicates the level of the field output, expressed as a
percentage of the maximum rated output.
Operating Status. The Operating Status controls and indicators include three buttons and three
corresponding indicators. Operating Status buttons are labeled PF, VAR, and OFF. Clicking the PF button
changes the color of the adjacent PF indicator to green and causes the DECS-100 to maintain the
desired power factor regulation point. The power factor regulation point can be set within the range of 0.6
lead to 0.6 lag. Clicking the VAR button changes the color of the adjacent VAR indicator to green and
causes the DECS-100 to maintain the desired var regulation point. The var regulation point can be set
within the range of 100 percent absorb to 100 percent generate. Clicking the OFF button changes the
color of the adjacent OFF indicator to red and disables power factor and var regulation.
Operation of the Operating Status controls is determined by the status of the contacts connected across
the DECS-100 Var/PF Control terminals (52J, 52K). When these contacts are open, the Operating Status
controls are enabled. Closing the contacts at terminals 52J and 52K disables the Operating Status
controls and interrupts regulation of vars or power factor until the contacts are opened again.
Setpoint - Voltage (V). This setting field can be used to enter the desired generator output terminal
voltage. The voltage setpoint can also be entered at the Setting Adjustments screen, Setpoint tab,
Automatic Voltage Regulator (AVR) - AVR Setpoint (V). The background color of this field is green when
operating in AVR mode and power factor and var regulation is disabled.
Setpoint - Current (A). This setting defines the field current setpoint when operating in FCR mode. The
current setpoint can also be entered at the Setting Adjustments screen, Setpoint tab, Field Current
Regulator (FCR) - FCR Setpoint. Current values from 0 to 7 Adc may be entered in increments of 0.01
Adc. The background color of this field is green when operating in FCR mode.
Setpoint - Var (% of nom.). This setting determines the level of generator vars maintained by the DECS-
100 when operating in var mode. The var setpoint can also be entered at the Setting Adjustments screen,
Setpoint tab, Reactive Power Control (VAR) - VAR Setpoint (% of nom.). The background color of this
field is green when the DECS-100 is operating in AVR mode and is regulating the var setpoint.
Setpoint - Power Factor. This setting determines the level of power factor regulation maintained by the
DECS-100. The power factor setpoint can also be entered at the Setting Adjustments screen, Setpoint
tab, Power Factor Control (PF) - PF Setpoint. Power Factor setpoint values are adjustable from -0.6 to -1
5-16 DECS-100 BESTCOMS Software 9287500991 Rev L
(1) or 0.6 to +1 in 0.001 increments. The background color of this field is green when the DECS-100 is
operating in AVR mode and is regulating the power factor setpoint.
Voltage Matching. The Voltage Matching controls and indicators consist of two buttons and two adjacent
indicators. Clicking the ON button changes the color of the adjacent ON indicator to green and enables
voltage matching by the DECS-100. When Voltage Matching is enabled, the DECS-100 automatically
adjusts the field current to match the generator output voltage with the bus voltage prior to synchronizing.
In order for Voltage Matching to be enabled, the following conditions must be met.
 The Parallel Generator Compensation Contacts (terminals 52L and 52M) must be shorted.
 The DECS-100 Voltage Matching input must be shorted (terminals VM and VMC).
 Var/PF control must be disabled by shorting terminals 52J and 52K (open breaker).
 The DECS-100 must be operating in AVR mode.
Clicking the OFF button changes the color of the adjacent OFF indicator to red and disables the voltage
matching function.
Control Mode. Clicking the AVR button changes the color of the adjacent AVR indicator to green and
enables the AVR operating mode. When operating in AVR mode, the DECS-100 regulates the generator
output voltage at the AVR setpoint. Clicking the FCR button changes the color of the adjacent FCR
indicator to green and enables the FCR operating mode. When operating in FCR mode, the DECS-100
maintains the field current at the FCR setpoint. Enabling the FCR mode turns off Voltage Matching.
Fine Adjustment. Raise and Lower buttons control the fine adjustment of the operating setpoint. These
buttons perform the same function as closing the appropriate set of contacts connected to the External
Adjust terminals (6D and 7 to decrease, 6U and 7 to increase) of the DECS-100. For AVR mode, each
click of the Raise button increases the voltage setpoint 0.01 volts; each click of the Lower button
decreases the voltage setpoint 0.01 volts. The minimum and maximum limits for fine adjustment of the
voltage setpoint are controlled by the Regulator Sensing Voltage setting (System Configuration screen)
and the Fine Voltage Adjustment - Band setting (Setting Adjustments screen). Fine adjustment of the
voltage setpoint can be increased/decreased no higher/lower than the Regulator Sensing Voltage setting
plus/minus the Band setting. For example, a Regulator Sensing Voltage setting of 100 volts and a Band
setting of 10 percent allows the Fine Adjustment function to increase the voltage setpoint to a maximum
of 110 volts and decrease the voltage setpoint to a minimum of 90 volts. For Var, PF, or FCR modes, the
Raise and Lower buttons provide fine adjustment over the entire adjustment range.
Alarm/Status Tab
The Alarm/Status tab indicators provide the status of DECS-100 protection functions, control modes, and
contact inputs. Alarm/Status tab indicators are illustrated in Figure 5-17 and are described in the following
paragraphs.
Protection Alarms. Six protection alarm indicators provide the status of DECS-100 protection functions.
Alarm indicators include Overexcitation Shutdown, Overexcitation Limiting, Underexcitation Limiting,
Generator Overvoltage, Loss of Generator Sensing, and Underfrequency. When a DECS-100 protection
function detects an alarm condition, the appropriate indicator changes from black to red.
Control Status. Two Control Status indicators indicate when the VAR/PF and Manual modes are active.
The Manual Mode Active indicator changes from black to red when the FCR control mode is active. The
VAR/PF Mode Active indicator changes from black to red when the DECS-100 is operating in AVR mode
and correction of power factor or vars is selected.
Switch Status. Three Switch Status indicators indicate when the DECS-100 control inputs are open or
closed. The 52JK switch open indicator changes from black to red when the user-supplied contacts at
terminals 52J and 52K are closed. When this control input is open, selection of PF or VAR mode can be
made on the Operation tab of the Metering, Operation, and Alarms screen. The 52LM switch closed
indicator changes from black to red when the user-supplied contacts at terminals 52L and 52M are
closed. When this control input is closed, parallel control and droop is inactive. The VM switch closed
indicator changes from black to red when the user-supplied contacts at terminals VM and VMC are
closed. When this control input is closed, the Voltage Matching function is active.
Metering Signal. The Metering Signal indicator flashes to indicate when metering is active. A number
beside the indicator tracks how many times the metering and status indicators have been updated. When
the Metering button is clicked or Metering on the Menu bar is clicked followed by Disable Metering, the
Metering Signal indicator stops flashing, the metering update counter stops incrementing, and the
metering functions stop being updated.

9287500991 Rev L DECS-100 BESTCOMS Software 5-17

 Figure 5-17. Metering, Operation, and Alarms Screen, Alarm/Status Tab

PID DATA
BESTCOMS enables generator stability to be set through the automatic calculation of PID parameters.
PID stands for Proportional, Integral, Derivative. The word proportional means that the response of the
DECS-100 output is proportional or relative to the amount of change that is observed. Integral means that
the DECS-100 output is proportional to the amount of time that a change is observed. Integral action
eliminates offset. Derivative means that the DECS-100 output is proportional to the required rate of
excitation change. Derivative action avoids excitation overshoot.
BESTCOMS automatically calculates PID values after the user selects the generator frequency,
generator time constant (T'do), and exciter time constant (Texc). With BESTCOMS, the user may
generate new PID numbers, add to a PID list file, and update the AVR gain settings in the Control Gain or
Step Response screens.
The PID window (Figure 5-18) is accessed by clicking the PID button. The PID button can be clicked only
when the Stability Range setting of the Control Gain screen is set at a value of 21. (A setting of 21
enables the entry of custom stability settings through the PID window.) Then, when a field of the Control
Gain screen is changed or selected, the PID button changes from gray to yellow and the button can be
clicked to view the PID window. After the PID numbers are modified, calculated, and updated, the PID
window is closed by clicking the Update Setting Screen button. The modified PID values are then shown
on the Control Gain screen.

PID Calculation Based on Input Values

The available range for the exciter time constant depends on the value entered for the generator time
constant. (The default value for the exciter time constant is the generator time constant divided by 6.) The
generator time constant value selected must be in the range of 1.00 to 15.00 seconds and in 0.05
increments. When the generator time constant value is 1.00, the available exciter time constant range is
0.03 to 0.50 in 0.01 second increments. When the generator time constant value is 15.00, the available
exciter time constant range is 0.30 to 3.00 in 0.01 second increments.
For example, when T'do is set at 2.0 seconds, Texc is 0.33. After specifying the input values, a set of PID
parameters (output data) is generated automatically. If T'do is set at 5.00 seconds, then Texc is 0.83
seconds. The calculated KP is 155.47, KI is 138.72, KD is 48, and Kg is 1.
PID parameters can be directly removed from, added to, or modified in the PID List Data. PID parameters
may also be saved into a file (pidlist.dat).

5-18 DECS-100 BESTCOMS Software 9287500991 Rev L

 Figure 5-18. PID Window

Adding to the PID List

CAUTION
Calculated or user-defined PID values are to be implemented only after their
suitability for the application has been verified by the user. Incorrect PID numbers
will result in poor system performance or system damage.

PID parameters can be added to a list and recalled for operation and comparison. To add to the list, type
a name for the generator (or other appropriate information) in the generator information box. Select the
generator time constant. Observe the PID gain parameters in the Field Output Data fields. If these gain
parameters are appropriate, click the Add to PID List button. Check for the new parameters by pulling
down the PID List (click the down arrow). The new gain and time constant parameters should be
displayed.

Removing a PID List Record

PID parameters can also be removed from the list. To remove a list (record), pull down the PID List and
select the record or list so that the gain and time constant parameters are displayed. Click the Remove
Record button and the listed record is deleted.

Retrieving Existing Data from the PID List

To retrieve existing data, pull down the PID List and select the record or list so that the gain and time
constant parameters are displayed and highlighted. Click the Get from a List button and the listed record
input and output data displays in the boxes.

SETTINGS FILES
BESTCOMS software enables you to print a list of DECS-100 settings, save DECS-100 settings to a file,
and open a settings file and upload those settings to a DECS-100. A settings file may also be opened and
edited within any text editing software.

Printing Settings Files

A printout of DECS-100 settings can be useful for record keeping or comparison purposes. DECS-100
settings are printed by clicking the print icon or clicking File on the Menu bar and then clicking Print.
When the print command is given, a dialog box provides the opportunity to add a title, unit information,
and comments to the settings list. Each entry is limited to a maximum of 54 characters. When OK is
clicked, a print dialog box prompts you to select a printer. Once the printer is selected, the report is
printed.
9287500991 Rev L DECS-100 BESTCOMS Software 5-19
Saving Settings Files
Saving DECS-100 settings to a file for uploading to other DECS-100 units saves setup time when
configuring multiple units to the same configuration. A settings file can also be created in BESTCOMS
without being connected to a DECS-100. The settings of the desired screens can be changed and these
settings can then be saved to a file. Once a settings file is created, it can be edited using any text editing
software, and then saved for uploading.
A settings file is created by clicking the save icon or by clicking File on the Menu bar and then clicking
Save. When the save command is given, a dialog box provides a choice of saving the settings in a
DECS-100 file or text file.
If “DECS File” is selected, a Save As dialog box appears and enables you to save the settings file. The
file is automatically given a .de1 extension.
If “Text File” is selected, a dialog box provides the opportunity to add a title, unit information, and
comments to the settings. Each entry is limited to a maximum of 54 characters. When OK is clicked, a
Save As dialog box appears and enables you to save the settings file. The file is automatically given a .txt
file extension.

Uploading Settings Files

A DECS-100 settings file downloaded from a DECS-100 or created within BESTCOMS can be uploaded
to multiple DECS-100 units. Only a DECS-100 settings file with a .de1 extension can be uploaded to a
DECS-100 unit. Before uploading a file, communication must be initiated with the DECS-100 that is to
receive the settings. Refer to the paragraphs labeled Starting BESTCOMS, Establishing Communication.

CAUTION
Before uploading a settings file, remove operating power from the DECS-100,
disconnect the field wiring from terminals F+ and F–, and re-apply operating
power to the DECS-100.

The upload process is started by clicking the open icon or clicking File on the menu bar and then clicking
Open. A dialog box is then displayed (Figure 5-19) reminding you that the DECS-100 should be off-line
before uploading settings. Clicking Yes loads the settings into DECS-100 memory.

Figure 5-19. Settings Upload Dialog Box

PASSWORD PROTECTION
Password protection guards against unauthorized changing or viewing of DECS-100 settings. A single
password protects all DECS-100 settings. The DECS-100 is delivered with a default password of decs.
Once the password is changed, it should be stored in a secure location. If the user-defined password is
lost or forgotten, BESTCOMS must be reloaded to restore the default password.

Changing the Password

NOTE
A password change can be made only after communication between
BESTCOMS and the DECS-100 is established.

A new password can be programmed by performing the following steps.

5-20 DECS-100 BESTCOMS Software 9287500991 Rev L

1. Click Communications on the menu bar and click
Password Change on the drop-down menu. The Change
Password dialog box of Figure 5-20 appears.
2. Type the current password in the "Enter your access
password" field of the Change Password dialog box and
press the Enter key on your keyboard.
3. Another dialog box will appear with instructions for making
the password change. Click the OK button and type a new
password (8 alphanumeric characters, maximum) in the
"Enter your new password" field.
4. Press the Enter or Tab key on your keyboard to advance the
cursor into the field labeled "Re-enter your new password".
Type the new password again to confirm the changed
password and press the Enter key. When the Enter key is
pressed, the new password is enabled and a dialog box
appears to remind you to keep your password in a secure Figure 5-20. Password Dialog Box
location.

TERMINATING COMMUNICATION
DECS-100 communication is terminated by clicking on Communications on the menu bar, and clicking
Close Comm Port. You are asked if you want to save the settings to EEPROM. This question is asked
even if no changes were made to the DECS-100 settings. When you execute the Close command (with a
Yes or No to save settings to EEPROM), communication with the DECS-100 is terminated. If you choose
to exit BESTCOMS (by clicking File on the menu bar and then Exit) without first closing communication,
you are still given the opportunity to save the settings to EEPROM.

EMBEDDED FIRMWARE
Embedded firmware is the operating program that controls the actions of the DECS-100. The DECS-100
stores firmware in nonvolatile flash memory that can be reprogrammed through the RS-232
communication port. It is not necessary to replace EPROM chips when replacing the firmware with a
newer version.

Updating the Firmware

Future enhancements to DECS-100 functionality may make a firmware update desirable. DECS-100
embedded firmware can be updated by performing the following steps.

CAUTION
If power is lost or communication is interrupted during file transfer, the DECS-100
will not recover and will cease to be operational.

NOTE
Communication must be closed prior to uploading embedded firmware to the
DECS-100. Refer to the Terminating Communication subsection for information
about closing DECS-100 communication.

1. Connect a communication cable between the rear RS-232 connector of the DECS-100 and the
appropriate communication port of your PC.
2. Click DECSLoad on the BESTCOMS menu bar and click Uploading Embedded Software. If this
menu selection is grayed out, you'll need to close DECS-100 communication. Refer to the
Terminating Communication subsection for information about closing DECS-100 communication.

9287500991 Rev L DECS-100 BESTCOMS Software 5-21

When Uploading Embedded Software is clicked, a dialog box (Figure 5-21) is displayed that advises
you to disconnect the DECS-100 generator and bus connections and save the DECS-100 settings in a file
before proceeding with firmware uploading. Firmware uploading may replace some user-adjusted settings
with factory-default settings.

Figure 5-21. Software Uploading Advisory Dialog Box

3. Click Yes to proceed with software uploading. When Yes is clicked, the Communication Initiation
screen (Figure 5-4) appears. Select the active communication port for your PC and click the Initialize
button. BESTCOMS obtains the configuration settings from the DECS-100 and saves all settings.
When the saving of settings is complete, the DECS-100 Embedded Program Loader of Figure 5-22
appears.

Figure 5-22. DECS-100 Embedded Program Loader

4. Click the Get Device Information button. The DECS-100 Embedded Program Loader retrieves and
displays the DECS-100 model number, style number, serial number, and application program version
number in the left-hand column (Figure 5-23).

Figure 5-23. Retrieved DECS-100 Information

5. Click the Start Transfer Data button to proceed with software uploading. The dialog box of Figure 5-
24 appears and recommends that your DECS-100 settings be saved in a file that can be uploaded to
the DECS-100 after the embedded firmware is updated.

5-22 DECS-100 BESTCOMS Software 9287500991 Rev L

 Figure 5-24. Settings File Reminder Dialog Box
Clicking No allows you to exit the upload process so that a DECS-100 settings file can be created. Refer
to the Settings Files subsection for information about creating a settings file.
Clicking Yes continues with the upload process and displays the Open dialog box of Figure 5-25. The
Open dialog box is used to locate and select the appropriate file for uploading to the DECS-100. Only files
with a .S19 extension are displayed in the Open dialog box.

Figure 5-25. Open Dialog Box

6. Select the appropriate file for uploading and click the Open button to start the file transfer. A dialog
box (Figure 5-26) indicating the progress of the file transfer is displayed.

Figure 5-26. File Transfer Progress

Once the transfer is complete, the device information is displayed in the right-hand column of the DECS-
100 Embedded Program Loader (Figure 5-26). The displayed program version number indicates the
version and date of the firmware just loaded.

9287500991 Rev L DECS-100 BESTCOMS Software 5-23

 Figure 5-27. DECS-100 Information After Upload
7. Close the DECS-100 Embedded Program Loader. BESTCOMS loads the default settings, loads the
saved settings, and checks the settings.

5-24 DECS-100 BESTCOMS Software 9287500991 Rev L

SECTION 6  MAINTENANCE AND TROUBLE-
SHOOTING
TABLE OF CONTENTS
SECTION 6  MAINTENANCE AND TROUBLESHOOTING .................................................................... 6-1
PREVENTATIVE MAINTENANCE ........................................................................................................ 6-1
TROUBLESHOOTING ........................................................................................................................... 6-1
Generator Voltage Does Not Build ..................................................................................................... 6-1
Low Generator Output Voltage........................................................................................................... 6-2
High Generator Output Voltage .......................................................................................................... 6-3
Poor Voltage Regulation .................................................................................................................... 6-3
Generator Output Unstable (Hunting) ................................................................................................ 6-3
Overexcitation Shutdown Indicator is Annunciating ........................................................................... 6-4
Loss of Generator Sensing Indicator is Annunciating ........................................................................ 6-4
Overexcitation Limiting Indicator is Annunciating............................................................................... 6-4
Underexcitation Limiting Indicator is Annunciating............................................................................. 6-5
Underfrequency Active Indicator is Annunciating............................................................................... 6-5
No Droop ............................................................................................................................................ 6-5
No Voltage Matching .......................................................................................................................... 6-6

9287500991 Rev L DECS-100 Maintenance and Troubleshooting i

 This page intentionally left blank.

ii DECS-100 Maintenance and Troubleshooting 9287500991 Rev L

SECTION 6  MAINTENANCE AND TROUBLE-
SHOOTING
PREVENTIVE MAINTENANCE
The only preventive maintenance required on the DECS-100 is to periodically check that the connections
between the DECS-100 and the system are clean and tight. DECS-100 units are manufactured using
state-of-the-art, surface-mount technology. As such, Basler Electric recommends that no repair
procedures be attempted by anyone other than Basler Electric personnel.

Storage / Electrolytic Capacitors

This device contains long-life aluminum electrolytic capacitors. For devices that are not in service (spares
in storage), the life of these capacitors can be maximized by energizing the device for 30 minutes once
per year.

TROUBLESHOOTING
If you do not get the results that you expect from the DECS-100, first check the programmable settings for
the appropriate function. Use the following troubleshooting procedures when difficulties are encountered
in the operation of your excitation system.

Generator Voltage Does Not Build

Step 1. Verify that all wiring is properly connected. Refer to Figures 4-6 through 4-10.
If wiring is improperly connected or loose, reconnect wiring properly.
If wiring connections are correct, proceed to Step 2.
Step 2. Verify that the generator is spinning at rated speed.
If the generator is not up to rated speed, increase generator speed to the rated value.
If the generator is spinning at rated speed, proceed to Step 3.
Step 3. For PMG power, check for correct input power to the DECS-100. Refer to Section 1, General
Information, Specifications for input power requirements.
If voltage is not present, refer to the generator manual for repair procedures (PMG system
only).
If voltage is present, proceed to Step 4.
Step 3a. If the DECS-100 is being shunt powered (non-PMG) mode, verify that the residual voltage
applied to the power input is at least 6 Vac.
If the applied voltage is less than 6 Vac, refer to the generator manual and flash the generator
field.
If the applied voltage is 6 Vac or greater, proceed to Step 4.
Step 4. Verify that no fuses are open.
Replace any open fuses.
If no fuses are open, proceed to Step 4.
Step 5. Verify that the front panel Overexcitation Shutdown indicator is not lit.
If the front panel Overexcitation Shutdown indicator (field voltage) is lit, check the generator
and/or load conditions. Interrupt input power or shut down the generator for a minimum of one
minute.
If the front panel Overexcitation Shutdown indicator is not lit, proceed to Step 6.
Step 6. Verify that the front panel Overexcitation Limiting indicator is not lit.
If the front panel Overexcitation Limiting indicator is lit, check the generator and load conditions.
Also check the field current limit setpoint for the correct level. Interrupt input power or shut
down the generator for a minimum of 1 minute.
If the front panel Overexcitation Limiting indicator is not lit, proceed to Step 7.
9287500991 Rev L DECS-100 Maintenance and Troubleshooting 6-1
Step 7. Verify that the DECS-100 soft start settings are correct. Too long of a soft start setting may give
the appearance of no buildup.
If the soft start settings are incorrect, adjust the settings.
If the soft start settings have no effect, proceed to Step 8.
Step 8. Replace the DECS-100 unit.
If replacing the DECS-100 unit does not correct the malfunction, then the generator is defective.
Consult with the generator manufacturer.

Low Generator Output Voltage

Step 1. Verify that the voltage adjustment is not set too low.
If the voltage adjustment is too low, adjust it to the correct setpoint.
If the voltage adjustment is correct, proceed to Step 2.
Step 2. Verify that the underfrequency knee setpoint is not greater than the generator frequency.
If the underfrequency setpoint is too high, adjust the setpoint below the rated generator
frequency.
If the underfrequency setpoint is correct, proceed to Step 3.
Step 3. Verify that the generator is spinning at rated speed.
If the generator is not up to rated speed, increase the generator speed to the rated level.
If the generator is spinning at rated speed, proceed to Step 4.
Step 4. For PMG power, check for correct input power to the DECS-100. Refer to Section 1, General
Information, Specifications for input power requirements.
If the DECS-100 input voltage is low, refer to the PMG manual for PMG repair (PMG system
only).
If the voltage is at the required level, proceed to Step 5.
Step 4a. If the DECS-100 is being shunt powered (non-PMG), verify that the power potential transformer
(if used) has the correct turns ratio, is sized properly, and is supplying the correct voltage level
to the power input.
If the turns ratio of the power potential transformer is incorrect, is sized too small, or is not
supplying the correct input power, replace the power potential transformer.
If the power potential transformer is correct, proceed to Step 5.
Step 5. Verify that the sensing potential transformer (if used) has the correct turns ratio and is operating
correctly.
If the turns ratio of the sensing potential transformer is incorrect, replace the sensing potential
transformer.
If the sensing potential transformer is operating correctly, proceed to Step 6.
Step 6. Verify that the front panel Overexcitation Limiting indicator is not lit.
If the front panel Overexcitation Limiting indicator is lit, check the generator and/or load
conditions. Also check the field-current limit setpoint for the correct level. Interrupt input power
or shut down the generator for a minimum of one minute.
If the front panel Overexcitation Limiting indicator is not lit, proceed to Step 7.
Step 7. Low generator output voltage may occur when operating in droop mode with an inductive load.
If the low voltage condition is not caused by the droop function, proceed to Step 8.
Step 8. Verify that the voltage setpoint is not being modified by application of voltage to the optional
Accessory Input.
If the low voltage condition is not caused by voltage applied to the Accessory Input, proceed to
Step 9.
Step 9. Replace the DECS-100 unit.

6-2 DECS-100 Maintenance and Troubleshooting 9287500991 Rev L

High Generator Output Voltage
Step 1. Verify that the voltage adjustment is not set too high.
If the voltage adjustment is too high, adjust it to the correct setpoint.
If the voltage adjustment is correct, proceed to Step 2.
Step 2. Verify that the sensing potential transformer (if used) has the correct turns ratio.
If the turns ratio of the sensing potential transformer is incorrect, replace the sensing potential
transformer with the correct one.
If the sensing potential transformer is correct, proceed to Step 3.
Step 3. High generator output voltage may occur when operating in droop mode with a capacitive load.
If the high voltage condition is not caused by the droop function, proceed to Step 4.
Step 4. Verify that the voltage setpoint is not being modified by application of voltage to the optional
Accessory Input.
If the high voltage condition is not caused by voltage applied to the Accessory Input, proceed to
Step 5.
Step 5. Replace the DECS-100 unit.

Poor Voltage Regulation

Step 1. Verify that the case of the DECS-100 is properly grounded.
If the DECS-100 is not properly grounded, connect a dedicated ground wire to the quarter-inch
fast-on connector labeled GND on the rear of the DECS-100 case.
If the DECS-100 is properly grounded, proceed to Step 2.
Step 2. Check for grounded field leads.
If the field leads are grounded, isolate them from ground.
If the field leads are not grounded, proceed to Step 3.
Step 3. If the DECS-100 is powered from a PMG, check for grounded PMG leads.
If the PMG leads are grounded, isolate them from ground.
If the PMG leads are not grounded, proceed to Step 4.
Step 4. Verify that the generator frequency is not dropping below the DECS-100 underfrequency
setpoint when load is applied to the generator.
If the generator frequency is dropping below the underfrequency setpoint, reduce the setpoint if
possible. Also check the prime mover and generator for proper sizing in relation to the applied
load.
If poor regulation is not related to DECS-100 underfrequency operation, proceed to Step 5.
Step 5. Verify that regulation is not being affected by normal droop operation.
If droop operation is not affecting regulation, proceed to Step 6.
Step 6. Replace the DECS unit.

Generator Output Unstable (Hunting)

Step 1. Verify that the governor for the prime mover is operating properly.
If the governor is not operating properly, troubleshoot using the manufacturer's suggested
procedures.
If the governor is operating properly, proceed to Step 2.
Step 2. Verify that the sensing and input power leads are connected securely.
If the sensing or input power leads are not connected securely, tighten the connections.
If the sensing or input power lead connections are secure, proceed to Step 3.
Step 3. Verify that the DECS-100 Stability Range is set to the proper range.
If the Stability Range setting is incorrect, reset the Stability Range.
If the Stability Range setting is correct, proceed to Step 4.

9287500991 Rev L DECS-100 Maintenance and Troubleshooting 6-3

Step 4. Verify that the Stability Level is properly set.
If the Stability Level is not properly set, reset the Stability Level.

Overexcitation Shutdown Indicator is Annunciating

Step 1. Check for generator overloading.
If the generator is operating with a larger than rated load, shed load.
If the generator is operating with a rated or less than rated load, proceed to Step 2.
Step 2. Verify that the generator exciter field voltage requirements are compatible with the DECS-100.
If the exciter field voltage requirements are not compatible with the DECS-100, contact Basler
Electric Customer Service for recommendations.
If the exciter field voltage requirements are compatible with the DECS-100, proceed to Step 3.
Step 3. Replace the DECS-100.
If replacing the DECS-100 does not correct the malfunction, proceed to Step 4.
Step 4. Refer to the generator manual. Generator is defective.

Loss of Generator Sensing Indicator is Annunciating

Step 1. Verify that the voltage sensing leads are properly connected.
If the sensing leads are not properly connected, correct the connections.
If the sensing lead connections are correct, proceed to Step 2.
Step 2. For single-phase sensing, verify that E2 and E3 are connected.
If E2 and E3 are not connected, connect them both to phase C sensing voltage.
If E2 and E3 are properly connected, proceed to Step 3.
Step 3. Verify that the sensing potential transformer (if used) has the correct turns ratio and is
functioning properly.
If the sensing potential transformer has the wrong turns ratio or is malfunctioning, replace it.
If the sensing potential transformer is correct and functioning properly, proceed to Step 4.
Step 4. Verify that the generator output voltage is present on all phases.
If the generator is missing a phase, refer to the generator manual. Generator is defective.
If generator output voltage is balanced on all phases, proceed to Step 5.
Step 5 Replace the DECS-100.

Overexcitation Limiting Indicator is Annunciating

Step 1. Check for generator overloading.
If the generator is operating with a larger than rated load, shed load.
If the generator is operating with a rated or less than rated load, proceed to Step 2.
Step 2. Verify that the DECS-100 output (field) current limit is not set too low.
If the output current limit setpoint is too low, adjust for the proper setting.
If the output current limit is set properly, proceed to Step 3.
Step 3. Verify that the generator exciter field current requirements are compatible with the DECS-100.
If the generator exciter field current requirements are not compatible with the DECS-100,
contact Basler Electric Customer Service for recommendations.
If the generator exciter field current requirements are compatible with the DECS-100, proceed
to Step 4.
Step 4. Replace the DECS-100.
If replacing the DECS-100 does not correct the malfunction, proceed to Step 5.
Step 5. Refer to the generator manual. Generator is defective.

6-4 DECS-100 Maintenance and Troubleshooting 9287500991 Rev L

Underexcitation Limiting Indicator is Annunciating
Step 1. Verify that the DECS-100 generator voltage setpoint is not being driven to a lower level.
The setpoint can be affected by the Raise/Lower contact inputs or by the Auxiliary input.
Step 2. Verify that the DECS-100 output (field) current limit is not set too low.
Adjust the field current limit as needed.
Step 3. Use the connection diagrams of Section 4, Installation to verify that the sensing voltage and
current connections to the DECS-100 provide the proper phasing.
Correct the sensing voltage and current connections as needed.
Step 4. Verify that the generator exciter field current requirements are compatible with the DECS-100.
If the generator exciter field current requirements are not compatible with the DECS-100,
contact Basler Electric Technical Sales Support for recommendations.
If the generator exciter field current requirements are compatible with the DECS-100, proceed
to Step 5.
Step 5. Replace the DECS-100.
If replacing the DECS-100 does not correct the malfunction, proceed to Step 6.
Step 6. Refer to the generator manual or contact the generator manufacturer.

Underfrequency Active Indicator is Annunciating

Step 1. Verify that the generator is operating at rated speed.
If the generator is not operating at rated speed, adjust the generator speed.
If the generator is operating at the rated speed, proceed to Step 2.
Step 2. Verify that the underfrequency setpoint is correct.
If the underfrequency setpoint is incorrect, adjust it to the correct value.

No Droop
Step 1. Verify that the DECS-100 52L/M contact input is open.
If the 52L/M contact input is not open, it must be opened to enable the droop function.
If the 52L/M contact input is open, proceed to Step 2.
Step 2. Verify that the DECS-100 52J/K contact input (if present) is closed or the Var/PF function is
disabled via BESTCOMS. Var/PF operation must be disabled for droop operation. If var/PF
operation is disabled, proceed to Step 3.
Step 3. Verify that the DECS-100 droop setting is not adjusted to 0% droop.
If the droop setting is adjusted to 0% droop, increase the setpoint above 0%.
If the droop setting is adjusted to above 0%, proceed to Step 4.
Step 4. Check for an open in the circuit connected to DECS-100 CT1 and CT2.
If there is an open circuit, repair as necessary.
If there is no open circuit, proceed to Step 5.
Step 5. Verify that all connections are correct according to Figures 4-6 through 4-9.
If connections are incorrect, correct the problem.
If connections are correct, proceed to Step 6.
Step 6. Verify that the load being applied to the generator for droop testing is not purely resistive.
If only a resistive load is being applied to the generator, apply an inductive load and retest.
If the load being applied to the generator is inductive, proceed to Step 7.
Step 7. Verify that your DECS-100 is compatible with the current sensing transformer (1 A or 5 A
secondary) being used. For example, a current sensing transformer with a 1 ampere output
rating would produce very little droop if your DECS-100 has a 5 ampere current transformer
input. Refer to Figure 1-1 to check the current transformer input of your DECS-100.

9287500991 Rev L DECS-100 Maintenance and Troubleshooting 6-5

 If the current transformer input is incorrect, replace the current sensing transformer or the
DECS-100 for compatibility.
If the current transformer input is correct, proceed to Step 8.
Step 8. If the above steps fail to correct the malfunction, replace the DECS-100 unit.

No Voltage Matching
Step 1. Verify that the Voltage Matching option was purchased and is enabled in the software.
If not enabled, use the BESTCOMS software to turn on voltage matching.
If voltage matching is enabled, proceed to Step 2.
Step 2. Verify that all connections are correct according to Figures 4-6 through 4-9 as required for the
Voltage Matching option of the DECS-100.
If the interconnection is incorrect, reconnect according to the appropriate interconnect diagram.
If the interconnection is correct, proceed to Step 3.
Step 3. Verify that the DECS-100 VM/VMC contact input is closed.
If the VM/VMC contact input is open, it must be closed to enable voltage matching.
If the VM/VMC contact input is closed, proceed to Step 2.
Step 4. Check for correct utility reference voltage on DECS-100 terminals B1 and B3.
If the interconnection is incorrect, reconnect according to the appropriate interconnect diagram.
If the interconnection is correct, check for open system fuses.
Verify that the potential sensing transformer, if used, is connected to DECS-100 terminals B1
and B3.
If potential sensing transformer connections are correct, proceed to Step 5.
Step 5. Verify that the generator output voltage setpoint is within 10 percent of the measured utility bus
voltage.
This page intentionally left blank.
If the setpoint is too low or too high, adjust
the setpoint to the appropriate level.
If the setpoint is correct, proceed to Step 6.
Step 6. If the above steps fail to correct the Voltage Matching malfunction, replace the DECS-100.

6-6 DECS-100 Maintenance and Troubleshooting 9287500991 Rev L

 ®

12570 State Route 143

Highland IL 62249-1074 USA
www.basler.com, [email protected]
Phone +1 618.654.2341 Fax +1 618.654.2351
Instructions
for Maintenance and Inspection

Slide Bearings Type EF

with external oil supply

RH
EFZWI
E
7.02
Maintenance and Inspection

RENK AKTIENGESELLSCHAFT
Werk Hannover
Weltausstellungsallee 21
D
30539 Hannover
Telephone: (0511) 8601
0
Telefax: (0511) 8601
266
e
mail: gleitlager.hannover@renk
ag.com
http:\\www.renk.de

All rights reserved. Copy or reproduction without prior permission of RENK Aktiengesellschaft Hannover
prohibited.

2 RH
EFZWI
E Version: 1 Juli, 2002 Ó RENK AG Werk Hannover

 EF with external oil supply

Contents

Bearing Coding ..............................................................................................................................................5

General Drawing of the EF Slide Bearing with External Oil Supply ...............................................................7
General Drawing of the Thrust Part with RD
Thrust Pads.............................................................................9
General Drawing of the Loose Oil Ring........................................................................................................11
General Drawing of the Floating Labyrinth Ring with Seal Carrier ..............................................................13
General Drawing of the Rigid Labyrinth Seal ...............................................................................................15
General Drawing of the Baffle ......................................................................................................................17
General Drawing of the Dust Flinger ............................................................................................................19
1 Considerations for Use ...........................................................................................................................21
2 Safety Instructions ..................................................................................................................................22
3 Operating Instructions after Standstill ..................................................................................................23
4 Maintenance Schedule ...........................................................................................................................24
5 Oil Change................................................................................................................................................25
6 Dismantling of the Bearing .....................................................................................................................26
6.1 Tools and equipment .......................................................................................................................26
6.2 Use of lifting equipment ...................................................................................................................26
6.3 Preparation for dismantling..............................................................................................................28
6.4 Dismantling of the shaft seal
outboard side ..................................................................................28
6.4.1 Floating labyrinth seal (Type 10) ...............................................................................................29
6.4.2 Floating labyrinth seal with dust flinger (Type 11).....................................................................29
6.4.3 Floating labyrinth seal with baffle (Type 12)..............................................................................29
6.4.4 Rigid labyrinth seal (Type 20) ....................................................................................................29
6.4.5 Rigid labyrinth seal with dust flinger (Type 21) .........................................................................29
6.4.6 Rigid labyrinth seal with baffle (Type 22) ..................................................................................29
6.5 Dismantling of the top half of the housing .......................................................................................30
6.6 Removal of the top half of the shell .................................................................................................30
6.6.1 Dismantling of the loose oil ring................................................................................................30
6.6.2 Dismantling the machine side shaft seal ..................................................................................31
6.7 Removal of the bottom half of the shell ...........................................................................................31
6.8 Dismantling of the machine seal ......................................................................................................31
7 Cleaning and Checking of the Bearing..................................................................................................32

Ó RENK AG Werk Hannover RH
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Maintenance and Inspection

8 Assembly of the Bearing.........................................................................................................................34

8.1 Fitting in the bottom half of the shell................................................................................................34
8.2 Assembly of the shaft seal
machine
side ......................................................................................35
8.3 Installation of the loose oil ring ........................................................................................................37
8.4 Fitting in the top half of the shell......................................................................................................38
8.5 Closing of the bearing ......................................................................................................................39
8.6 Assembly of the Seals
Outboard Side...........................................................................................41
8.6.1 Floating labyrinth seal (Type 10) ...............................................................................................41
8.6.2 Floating labyrinth seal with dust flinger (Type 11).....................................................................45
8.6.3 Floating labyrinth seal with baffle (Type 12)..............................................................................46
8.6.4 Rigid labyrinth seal (Type 20) ....................................................................................................46
8.6.5 Rigid labyrinth seal with dust flinger (Type 21) .........................................................................48
8.6.6 Rigid labyrinth seal with baffle (Type 22) ..................................................................................48
9 Starting Operation after Inspection.......................................................................................................49
10 ...Corrosion Protection for Longer Standstill Periods ............................................................................50
11 ...Transport Protection...............................................................................................................................50
12 ...Glossary ...................................................................................................................................................51

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 EF with external oil supply

Bearing Coding

Ó RENK AG Werk Hannover RH
EFZWI
E Version: 1 Juli, 2002 5

Maintenance and Inspection

Œ  Ž   ‘

Type Housing Heat Dissipation Shape of Bore and Type of Thrust part Size
Diameter
Lubrication

E F
flange mounted Z
lubrication by oil circulation with C
plain cylindrical bore Q - without thrust part 9 80£D£100
bearing external oil cooling without oil ring (non locating bearing )
11 100£D£125
X
lubrication by oil circulation with L
plain cylindrical bore with B - plain sliding surfaces
external oil cooling when (locating bearing) 14 125£D£160
loose oil ring
oil throughput is high
E
taper land faces for one
Y
two
lobe bore (”lemon bore”) 18 160£D£200
U
circulating pump and natural sense of rotation
without oil ring
cooling (locating bearing)
22 200£D£250
V
four
lobe bore K - taper land faces for both
T
circulating pump and water without oil ring 28 250£D£315
senses of rotation
cooling (finned cooler in
(locating bearing)
oil sump)
A - elastically supported circular
tilting pads (locating bearing)

Example for bearing coding:

Œ  Ž   ‘
E F Z L K 22
200 Type E slide bearing with flanged mounted housing, lubrication by
oil circulation with external oil cooling, plain cylindrical bore with loose
oil ring, locating bearing with taper land faces, size 22, diameter 200.

Shaft seals Type 10
floating labyrinth seal (IP 44)

Type 11
floating labyrinth seal with dust flinger (IP 54)
Type 12
floating labyrinth seal with baffle (IP 55)

Type 20
rigid labyrinth seal (IP 44)

Type 21
rigid labyrinth seal with dust flinger (IP 54)
Type 22
rigid labyrinth seal with baffle (IP 55)

6 RH-EFZWI-E Version: 1 Juli, 2002 Ó RENK AG Werk Hannover

 external oil supply

General Drawing of the

EF Slide Bearing

with external oil supply

Ó RENK AG Werk Hannover RH
EFZE/WI
E Version: 1 Juli, 2002 7

 5 6 7 8 9

4
10

11

3 12

13
2
14

15
1
16

17
xxx

x
18
31 xxx

19

30
20

29 21

22

23

24

28 27 26 25
 1 Top half of the housing
2 Hole for positioning pin
3 Positioning pin
4 Connection hole for the oil supply of the thrust part
5 Top sight glass
6 Eye bolt
7 Screw (not included in delivery)
8 Screw
9 Tapped hole ( in the top and bottom halves of the shell, up size 14 )
10 Machine seal
11 Top half of the shell
12 Screw (split line of the housing)
13 Bottom half of the shell
14 Spherical seating
15 Engraved number
shell
16 Spigot
17 Tapped hole
18 Screw (not included in delivery)
19 Screw (split line of the shell)
20 Engraved numbers
housing
21 Bottom half of the housing
22 Tapped hole for temperature measurement of the journal part
23 Oil inlet connection hole
24 Tapped hole for the oil sump temperature measurement
25 Outlet/Inlet cooling water (Type E.T..)
26 Cooler ( Type E.T..)
27 Hexagon head plug (Oil drain plug)
28 Metal tabs ( optional for EFZL. )
29 Oil outlet connection hole
30 Oil outlet pipe with lock nut and lead seal
31 Marking
 external oil supply

General Drawing of the

Thrust Part with Circular Tilting Pads

(RD
Thrust Pads)

Ó RENK AG Werk Hannover RH
RDZE/WI
E Version: 1 Juli, 2002 9

37

38

39

40

41

42

43
37 Carrier ring
38 Location groove
39 Shroud ring top half
40 Screw
41 Shroud ring bottom half
42 Circular tilting pad (RD
thrust pad)
43 Anti
Rotation pin
 external oil supply

General Drawing of the

Loose Oil Ring

Ó RENK AG Werk Hannover RH
LSZE/WI
E Version: 1 Juli, 2002 11

44

45

46

47
44 Loose Oil Ring
45 Dowel pin
46 Hole
47 Screw
 external oil supply

General Drawing of the

Floating Labyrinth Seal

with Seal Carrier

Ó RENK AG Werk Hannover RH
SSZE/WI
E Version: 1 Juli, 2002 13

 Bearing side
48

49
54

53

50

52

51

Outer view
58 55

57

56
48 Seal carrier
top half
49 Garter spring
50 Groove
51 Seal carrier
bottom half
52 Bottom half of the seal
53 Top half of the seal
54 Anti
rotation pin
55 Screw
56 Engraved number
57 Groove ( Type 11 )
58 Engraved number
 external oil supply

General drawing of the

Rigid Labyrinth Seal

Ó RENK AG Werk Hannover RH
KDZE/WI
E Version: 1 Juli, 2002 15

 59
60

65

61 (2x)

62

64

63
59 Rigid labyrinth seal
top half
60 Screw
61 Screw (split line)
62 Groove ( Type 21 )
63 Rigid labyrinth seal
bottom part
64 Engraved number
65 Engraved number
 external oil supply

General Drawing of the

Baffle

Ó RENK AG Werk Hannover RH
DSZE/WI
E Version: 1 Juli, 2002 17

 66

67

68
66 Baffle
top half
67 Screw
68 Baffle
bottom half
 external oil supply

General Drawing of the

Dust Flinger

Ó RENK AG Werk Hannover RH
LRZE/WI
E Version: 1 Juli, 2002 19

 69

70 (2x)
69 Dust flinger
70 Screw (split line)
 EF with external oil supply

1 Considerations for Use

The instructions for maintenance and inspection are addressed to qualified technical personnel
(fitters, mechanic installers, mechanical engineers).

Read these instructions carefully before starting assembly.

Slide bearings of type EF are almost universally used in the engineering industry. Therefore it is not
possible to provide detailed information on all possible types and range of applications for these
bearing types. For instance, the position of the connection points for supply and monitoring
equipment is determined by the place of application ( in the following called " installation " ).
Please keep ready the guidelines with the technical documentation before starting assembly and
operation of the slide bearings.

Additional technical documentation with detailed information is supplied in the case of special
design bearings. Please contact RENK Export or Domestic Department for supplementary
information on bearings. Please indicate the bearing coding and the full reference number, too.

Following indications should be observed when reading these instructions.

Safety instructions are marked as follows:

Danger!
Warning of dangers for personnel.
Example: Warning of injury

Attention!
Warning of damage for the bearing or installation.

Useful recommendations and additional information are framed.

EF..Q This is how chapters, instructions or recommendations are marked when referring to a single type
or size of a bearing.
Example: Slide bearing type EF without thrust part ( non
locating bearing )

Instruction follows.

· Beginning of an enumeration.

( ) This is how the different parts of a bearing as described in the general drawings ( numbers )
are marked in the text.

- Use the enclosed check
list before starting assembly or operation. Copies available on request.
- The check list provides the experienced mechanical fitters of RENK bearings with the
necessary instructions for installation and operation.

Ó RENK AG Werk Hannover RH
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Maintenance and Inspection

2 Safety Instructions

Danger!
The maintenance and inspection of the slide bearings should be carried out by:
· persons nominated by the safety representative
· persons correspondingly trained and instructed
· persons with knowledge on appropriate standards, regulations and accident
prevention rules
· persons with knowledge on first
aid measures and local rescue centres.

Warning of injury!
Before starting work on the bearing:

Switch off the installation.

Make sure the installation is not in operation.
Never lift or transport machines, etc.by the bearing eye bolts. These are only intended
for assembly and dismantling of the bearing !

Warning of injury!
Do not grab such heavy bearing parts as the housing during assembly or dismantling
work. This could result in bruising or injury to hands !

Attention!
All metal parts of a slide bearing consisting of top and bottom part such as the housing, shells,
shaft seals are marked by engraved numbers. Fit together only the parts with the same number.

Attention!
In case · the admissible bearing temperature exceeds by 15 K
· inadmissible vibrations occur
· unusual noises or odours are noticed
· monitoring equipment triggers alarm
shut down the installation and inform the maintenance personnel in charge.

Attention!
Do not operate the bearing below the transition speed values indicated in the bearing calculation,
thus avoiding inadmissible operating conditions, which could lead to damage of the bearing.

Attention!
Please observe our leaflet Technical Information No. 85 which refers to various sealing compounds
for extended technical applications.

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 EF with external oil supply

3 Operating Instructions after Standstill

- Clean the external parts of the bearing. Dust and dirt impede the radiation of the heat.
- Check with the instructions to determine if an oil change is necessary. Depending on the
duration of the standstill an oil change is either prescribed or recommended. Carry out the oil
change as indicated in Chapter 5.
- Retighten the screws (8), (18), (12) at the split line and flange to the following torque rates:

Bearing Size 9 11 14 18 22 28

Torque [Nm] for 69 69 170 330 570 1150

µtot = 0,1 (lightly oiled)

- Check that the top sight glass (5) is firmly in position.

- Retighten the connection holes for oil inlets and outlets, the oil supply hole for the thrust part
(optional). The necessary torque rates depend on the used pipe joints.
- In case a thermo sensor or/and an oil sump thermometer are used:
- Check that they are correctly fitted (see also the manufacturer's instructions).
- Retighten all screw plugs in the connection holes (22), (24), (27), (29) to the necessary torque
rates:

Screw plug threads G 3/8 G 1/2 G 3/4 G1 G 1 1/4 G 1 1/2 G2 G 2 1/2

Torque [Nm] for plugs 30 40 60 110 160 230 320 500

with injection
moulded
plastic sealing ring

Torque [Nm] for plugs 34 60 85 130 240 300 330 410

with flexible sealing ring

- Start operating the oil supply system and check its functioning ( see also the Technical
Documentation of the Installation ). The supplied oil quantity at the bearing oil inlet must
correspond to the values indicated in the EDP
calculations.
- Check that the temperature monitoring equipment is functioning correctly
EFT.. - Check that the cooler is functioning correctly.

The bearing is now ready to work.

Ó RENK AG Werk Hannover RH
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Maintenance and Inspection

4 Maintenance Schedule

Maintenance work Deadline

Exterior cleaning of the bearing every 100
1000 hours

Oil change Bearing in reversing operation every 5000 operating hours.

Bearing in continuous operation every 20.000 operating hours
(please observe also the indications for the use of the
lubricating oil).

Bearing inspection During prevention maintenance work for the installation.

Immediately if:

· the bearing temperature exceeds 15 K over the indicated

value (see the EDP
calculations)

· unusual operating noises occur

· unusual changes of the lubricating oil become visible

· increased oil level in the case of bearing type EFT....

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 EF with external oil supply

5 Oil Change

Risk of pollution!
Please observe the instructions for the use of the lubricating oil. The manufacturer can provide
information on waste oil disposal.

- Shut down the installation and secure it against unintended operation.

- Shut down the oil supply system.
- Take all necesarry measures to collect the whole quantity of the lubricating oil.
- Drain off the lubricating oil while still in a warm condition. Impurities and residues will thus be
scavenged. Go ahead as follows:
- Drain off and collect the lubricating oil of the oil supply system.
- Unscrew the hexagon head plug (27). Drain off the lubricating oil and collect it.

Attention!
In case where the lubricating oil contains unusual residues or is visibly changed, eliminate the
causes. If necessary, carry out an inspection.

- Tighten the hexagon head plug (27) to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 30 30 30 40 60 60

- Clean the oil tank.

- Fill up the oil supply system with lubricating oil. Use a lubricant with the viscosity indicated on
the bearing type plate.
- Start the oil supply system in order to fill up the bearing with lubricating oil.

The bearing is ready to work when the quantity of oil supplied at the bearing oil inlet corresponds
to the values indicated in the EDP
calculations.

Ó RENK AG Werk Hannover RH
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Maintenance and Inspection

6 Dismantling of the Bearing

6.1 Tools and equipment

- Following tools and equipment are necessary:

· Allan key set
· Wrenching key set
· Open
jawed spanner set
· Feeler gauges (up 0,05 mm)
· Caliper gauge
· Emery paper, plain scraper
· Oil stone
· Lifting equipment
· Permanent sealing compound
· Clean (close weave) rags
· Oil with the viscosity indicated (see bearing type plate)
· Detergents
· Liquid screw locking compound (e.g.LOCTITE 242)
· Liquid sealing compound and Teflon tape.

6.2 Use of lifting equipment

Risk of injury!

Before transport or lifting check if the eye bolts are tight! Insecure eye bolts could
result in bearing becoming loose.

Before moving the bearing by the eye bolts make sure that the split line screws are
tightened, otherwise the bottom half of the bearing could become detached.
Make sure that the eye bolts are not exposed to bending stress, otherwise the bolts
could break.

Follow exactly the instructions for the use of the lifting equipment.

- Use lifting equipment for following assembly and transport works:

Transport/Assembly of: Use lifting equipment for the following bearing sizes

Whole bearing unit 9
28

Top half of the housing 14
28

Bottom half of the housing 11
28

Shells 14
28

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 EF with external oil supply

- Following steps are to be observed before using the lifting equipment:

Whole bearing unit

- Check if the screws are tight (12):

Bearing size 9 11 14 18 22 28

Torque value [Nm] for 69 69 170 330 570 1150

µtot = 0,1 (lightly oiled)

- Check if the eye bolts are tight (6).

- Connect the lifting equipment to the eye bolts (6).

Top half of the housing

- Check if the eye bolts are tight (6).
- Connect the lifting equipment to the eye bolts (6).

Bottom half of the housing

- Screw two eye bolts (6) with suitable threads tight into the cross
placed opposite tapped holes
(17).

Bearing size 9 11 14 18 22 28

Tapped hole M 12 M 12 M 16 M 20 M 24 M 30

- Connect the lifting equipment to the eye bolts (6).

Shells
- Screw two eye bolts or screw hooks with suitable threads tight into the tapped holes (9):

Bearing size 14 18 22 28

Tapped hole M8 M 12 M 12 M 16

- Connect the lifting equipment to the screw hooks.

Ó RENK AG Werk Hannover RH
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 Maintenance and Inspection

6.3 Preparation for dismantling

Attention!
Make sure that the work place is clean. Contamination and damage to the bearing, especially to
the working surfaces, have a negative influence on the operating quality and could lead to
premature failure.

Attention!
Do not use any violence or force!

- Shut down the installation and ensure it against unintended operation.

- Shut down the oil supply system.
EFT..
- Interrupt the cooling water supply.
- Disconnect all thermo sensors from the tapped holes.
- Take all necessary measures to collect the lubricating oil.
- Unscrew the hexagon head plug (27) and collect the lubricating oil.

Risk of pollution!
Please observe the instructions for the use of the lubricating oil. The manufacturer can provide
necessary information on waste oil disposal.

- Tighten the hexagon head plug (27) to the following torque rates

Bearing size 9 11 14 18 22 28

Torque (Nm] 30 30 30 40 60 60

- Inform yourself about maintenance and inspection of the oil supply system ( see also the
Technical Documentation Oil Supply System ). Carry out all necessary maintenance and
inspection works.

6.4 Dismantling of the shaft seal
outboard side

- Dismantle the outboard side seals of the bearing.

Proceed correspondingly to the seal type:
· Floating labyrinth seal (Type 10) Chapter 6.4.1
· Floating labyrinth seal with dust flinger (Type 11) Chapter 6.4.2
· Floating labyrinth seal with baffle (Type 12) Chapter 6.4.3
· Rigid labyrinth seal (Type 20) Chapter 6.4.4
· Rigid labyrinth seal with dust flinger (Type 21) Chapter 6.4.5
· Rigid labyrinth seal with baffle (Type 22) Chapter 6.4.6

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 EF with external oil supply

Type 6.4.1 Floating labyrinth seal (Type 10)

10
- Loosen all screws (55) and take them out.
- Remove simultaneously in axial direction both top half (48) and bottom half (51) of the seal
carrier from the housing.
- Shift a little (about 20 mm) the top half (53) of the seal. Tilt it over carefully until the garter spring
(49) unbends.

Warning of injury!
During dismantling of the floating labyrinth seal hold tight the garter spring (49) which
is under tension and could bounce back and lead to injury.

- Open the garter spring (49) and remove the bottom half of the seal (52) from the shaft.

Type 6.4.2 Floating labyrinth seal with dust flinger (Type 11)
11
- Dismantle the dust flinger (69). Loosen the screws (70) and take out the dust flinger (69) from
the groove (57) of the seal carrier.Remove both halves of the dust flinger.
- Go on as indicated for type 10 (see Chapter .4.1).

Type 6.4.3 Floating labyrinth seal with baffle (Type 12)

12
- Disconnect both top 66) and bottom (68) halves of the baffle by untightening the screws (67).
- Go on as indicated for type 10 (see Chapter 6.4.1).

Type 6.4.4 Rigid labyrinth seal (Type 20)

20
- Loosen all screws (60) and take them out.
- Take out the screws (61).
- Remove simultaneously in axial direction both top (59) and bottom (63) halves of the rigid
labyrinth seal.

Type 6.4.5 Rigid labyrinth seal with dust flinger (Type 21)
21
- Dismantle the dust flinger (69). Loosen the screws (70) and take out the dust flinger (69) from
the groove (62) of the rigid seal. Remove both halves of the dust flinger.
- Go on as indicated for type 20 (see Chapter 6.4.4).

Type 6.4.6 Rigid labyrinth seal with baffle (Type 22)

22
- Unscrew the top half (66) and the bottom half (68) of the baffle by untightening the screws (67).
- Go on as indicated for type 20 (see Chapter 6.4.4).

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 Maintenance and Inspection

6.5 Dismantling of the top half of the housing

EF.V. - Unscrew the screw plug with the welded
on positioning pin.
- Remove the screws (8).
- Remove the screws (12).
- Lift the top part of the housing (1) until the top part of the housing can be moved in axial line
over the shell, without touching it.

6.6 Removal of the top half of the shell

- Unscrew the screws (19) and lift the top half of the shell (11).

Attention!
Do not damage the thrust and radial working surfaces.

Attention!
In the case of insulated housings (white plastic insulating foil) avoid any jamming of the top half of
the shell when you lift it up.
Jamming could lead to damage of the insulating foil in the bottom half of the housing.

EF.L. 6.6.1 Dismantling of the loose oil ring

- Open both split lines of the loose oil ring (44) by untightening and taking out the screws (47).
Separate both halves of the loose oil ring (44) carefully without using any tools or other devices.

I II

44

44 44

47

Illustration 1 Opening of the loose oil ring

To check the geometry of the loose oil ring put it together as follows:
- Press the positioning pin (45) into the holes (46).
- Adjust both halves of the loose oil ring till the split lines match each other.
- Tighten the screws (47).

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6.6.2 Dismantling the machine side shaft seal

- Shift a little (about 20 mm) the top half (53) of the seal. Tilt it over carefully until the garter spring
(49) unbends.

Warning of injury!
During dismantling of the floating labyrinth seal hold tight the garter spring (49) which
is under tension and could bounce back and lead to injury.

- Open the garter spring (49) and turn the bottom half of the seal (52) in opposite direction from
the anti
rotation pin out of the integrated seal groove of the bottom half of the housing.

6.7 Removal of the bottom half of the shell

Attention!
Make sure that all bearings mounted on a shaft line are opened. Loosen the screws at the split line
of the housings.

Attention!
The lifting equipment should not come into contact with the seal and working surfaces of the shaft.

- Lift the shaft up to the point where shaft and bottom half of the shell (13) do not touch each
other any more. Protect the shaft against unintended movement.
- Turn the bottom half of the shell (13) out of the bottom half of the housing (21) and remove it
from the shaft.

Attention!
If the bottom half of the shell (13) is provided with metal tabs (28) do not remove them. They
regulate the oil level in the oil pockets.

6.8 Dismantling of the machine seal

Usually it is not necessary to dismantle the machine seal (10) if maintenance works are carried out.
If due to certain reasons the split machine seal must be dismantled please observe that this
operation can be carried out only from the inner part of the machine. Loosen the screws at the
split line of the machine seal and remove the screws (7).

Non
split machine seals can be dismantled only after dismantling the machine shield or the shaft
completely.
In the case the machine seal is equipped with a hamp packing, some visible changes can be
noticed, such as : tallow excess, black colour of the seal due to temperature development. Even in
such cases it is not necessary to renew the hamp packing. Colour changes will appear with a new
hamp packing too, until the seal clearance adjusts during operation.

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7 Cleaning and Checking of the Bearing

Attention!
Use only non
aggressive detergents such as for instance
· VALVOLINE 150
· Alcaline cleaning compounds (pH
value 6 to 9, short reaction time).

Warning of injury!
Please observe the instructions for the use of the detergents.

Attention!
Never use cleaning wool or cloth. Residues of such materials left in the bearing could lead to
excessive temperatures.

- Clean the following parts thoroughly:

· top half of the housing (1)
· bottom half of the housing (21)
· top half of the shell (11)
· bottom half of the shell (13)
· sealing surfaces of the top half (48) and bottom half (51) of the seal carrier or of the rigid
labyrinth seal
EF.L. · loose oil ring (44).

EFT.. - Check the condition of the cooler (26).

In case the cooler (26) is incrusted with oil sludge:
- Dismantle the cooler. Remove the incrustation by using for instance a wire brush.
- Install the cooler (26) into the bearing.

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- Carry out a visual check of the wear condition of all bearing parts. The following table provides
information on the parts that must be replaced in case of wear.The right evaluation of the wear
condition, especially of the working surfaces of the shell, implies a lot of experience. If in doubt,
replace the worn part with new ones.

Bearing part Wear condition Maintenance procedure

Shell Scoring Bearing temperature before inspection:

· not increased
no new shells
· increased
new shells

White metal lining damaged New shell

Bow wave ridges New shells

Shaft seal Baffles broken or damaged New shaft seal

Loose oil ring Geometrical form ( roundness, New loose oil ring
flatness ) visibly changed

EF.C. - Check the projection of the positioning pin (3) according to the rates indicated below:
EF.L.
EF.Y. Bearing size 9 11 14 18 22 28
Size
9
14 Projection of the 7 8 10 12 14 16
positioning pin (4) mm

In case the projection is less than indicated,

- drive the positioning pin (3) into the top half of the housing (1) until the indicated value is
reached.
insulated
bearings
- Check the insulating layer of the spherical seating (14) of the top half (1) and bottom half (21) of
the housing. In case of damage contact the RENK
sales agency in charge.

EF..A - Check the mobility of all RD
thrust pads (42).

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8 Assembly of the Bearing

Attention!
Remove all impurities or other objects such as screws, nuts, etc. from inside the bearing. If left
inside they could lead to damage of the bearing. Cover up the opened bearing during work breaks.

Attention!
Carry out all assembly operations without making use of force.

Attention!
Secure all screws at the split line, of the housing and flange with a liquid screw locking compound
(e.g.LOCTITE 242).

8.1 Fitting in the bottom half of the shell

EF..E Attention!
Mounting the bottom half of the shell (not marked with an arrow) correctly will ease the assembly
of the top half shell (marked with an arrow) (see chapter 8.4).

- Apply some lubricant to the spherical seating (14) in the bottom half of the housing (21) and to
the working surfaces of the shaft. Use the same type of lubricant as indicated for bearing
operation
( see type plate ).
- Place the bottom half of the shell (13) on the working surface of the shaft. Turn the bottom half
of the shell (13) into the bottom half of the housing (21) with the split line surfaces of both halves
in true alignment.

In case the bottom half of the shell doesn`t turn in easily, check the position of the shaft and the
alignment of the housing

EF..B, Attention!
EF..K, These operations should be carried out most carefully. The thrust parts of the bottom shell must
EF..E, not be damaged.
EF..A
- Lower down the shaft till it sits on the bottom half of the shell (13).

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8.2 Assembly of the shaft seal
machine
side

The machine
side shaft seal, as standard, a floating labyrinth seal. The integrated seal groove is in
the top and bottom halves of the housing.

Warning of injury!
During assembly hold the garter spring ends (49) securely to avoid them suddenly
releasing and causing possible injury!

Check the movement of the floating labyrinth seal on the shaft in the seal area outside the housing:
- Put the garter spring (49) around the shaft and hook both ends into each other.
- Put both halves of the seal (52), (53) in their place on the shaft.
- Put the garter spring (49) into the groove (50).
- Turn the floating labyrinth seal on the shaft.

Attention!
The floating labyrinth seal should turn easily on the shaft. A jammed seal could lead to overheating
during operation and even to shaft wear.
If the floating labyrinth seal jams,

dismantle the seal and

remove the worn parts of the seal carefully, by using emery paper or a plain scraper.

- Dismantle the floating labyrinth seal.

- Apply sealing compound to the guide surfaces of the integrated seal groove in the bottom half
of the housing.

Illustration 2: Applikation of sealing compound to the integrated seal groove

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Maintenance and Inspection

- Apply a uniform layer of sealing compound to the seal surfaces and to the split line surfaces of
both halves of the seal (52), (53).

Illustration 3: Application of sealing compound to the floating labyrinth seal

Please observe the instructions for the use of sealing compound.

- Place the bottom half of the seal (52) with the labyrinths onto the shaft.
- The oil return holes at the bearing side must be clear and open.
- Turn the seal in opposite direction from the anti
rotation pin into the groove of the housing until
the split lines of the bottom half of the housing and the bottom half of the seal match each
other.
- Remove the residue of sealing compound.
- Push the spring hook into the integrated groove between the bottom half of the housing and
the seal until both ends jut out from the split line.
- Place the top half of the seal with the cam facing the inside of the bearing on the bottom half of
the seal.
- Stretch the garter spring till both ends can be hooked.

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EF.L. 8.3 Installation of the loose oil ring

- Open both split lines of the loose oil ring (44) by untightening and removing the screws (47).
Separate both halves of the loose oil ring (44) carefully without using any tools or other devices.

I II

44

44 44

47

Illustration:4 Opening of the loose oil ring

- Place both halves of the loose oil ring into the shell groove (13) around the shaft. Press the
positioning pin (45) of each split line into the corresponding hole (46).
- Adjust both halves of the loose oil ring till the split lines match each other.

21
45

44

44 18

Illustration 5: Installation of the loose oil ring

- Tighten the screws (47) to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 1,4 1,4 1,4 2,7 2,7 2,7

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 Maintenance and Inspection

8.4 Fitting in the top half of the shell

- Apply some lubricant to the working surfaces of the shaft. Use the same type of lubricant as
indicated for bearing operation (see type plate).
- Check if the engraved numbers (15 ) on the bottom and top halves of the shell correspond.
- Place the top half of the shell (11) on the shaft; both engraved numbers (15) should be on the
same side.

Attention!
An incorrectly placed shell could jam the shaft thus leading to the damage of both shaft and
bearing.

EF..B,
EF..K, Attention!
EF..E, Place the top half of the shell carefully on the shaft. The thrust parts of the top half of the shell
EF..A must not be damaged.

insulated
In the case of bearings arranged for insulation monitoring, connect the black cable for insulation
bearings
monitoring to the shell.
According to the bearing type, there are two possibilities of connection.
1. The black cable is provided with a cable connector.
- Plug the cable with the cable connector into the counterpart available on the top of the shell.
- Lead the cable through the cable gland in the bottom half of the housing and out of the
bearing.
- Tighten the cable gland oil
tight.
2. The black cable is provided with an eyelet.
- Fasten the cable with the eyelet to the split line of the shell, by using one of the shell joint bolts.
- Lead the cable through the cable gland in the bottom half of the housing and out of the
bearing.
- Tighten the cable gland oil
tight.

- Tighten up the screws (19) to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 8 8 20 69 69 170

- Check the split line of the shell by using a feeler gauge. The split line gap should be less than
0,05 mm. If the split line is greater than this, dismantle both top and bottom (11), (13) halves of
the shell. Rework the split line surfaces of the top half (11) and bottom half (13) of the shell with
an oil stone.
EF.L.
- Check the mobility of the loose oil ring (44).

EF.L. A guide bush in the top half of the shell secures the function of the loose oil ring.
Marine
Bearing - Check the mobility of the loose oil ring (44) in the guide bush.

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EF..E Shells with taper land faces suitable only for one direction of rotation are marked with an arrow on
the top half shell, which indicates the sense of rotation of the shaft.
The arrow indicates the allowed direction of shaft rotation after completion of the bearing
assembly.
- Before mounting the top half of the housing check that the proposed direction of rotation of the
shaft corresponds to the direction indicated by the arrow on the top half of the shell.
- If the directions match, continue the assembly of the bearing.
- If the directions do not match, the shell must be disassembled, re
aligned and mounted again.

Attention!
A wrongly placed shell, without observance of the direction of rotation of the shaft, impairs the
operational safety of the bearing.

8.5 Closing of the bearing

- Check the true alignment of the shell (11), (13) and bottom half (21) of the housing.

EF.C. The positioning pin (3) in the top half of the housing fits in the corresponding hole (2). The shell is
EF.L. thus placed into its right position.
EF.Y.
- Check if the engraved numbers (20) on the top and bottom halves of the housing correspond.
- Clean the split line surfaces of the top and bottom halves (1), (21) of the housing.
- Apply sealing compound to the whole surface of the split line of the bottom half (21) of the
housing.

Please observe the instructions for the use of sealing compound.

- Place the top half of the housing carefully into the machine shield, without touching the seals or
the shell.
- Lower the top half of the housing (1) vertically on the bottom half of the housing (21). Lower the
top half of the housing (1) till the split line of the housing is not visible any more.
- Gently hit the bottom half of the housing (21) with a nylon hammer, thus ensuring the alignment
of the spherical seating.
- Insert the screws (12). Tighten them hand
tight.
- Insert the screws (8). Tighten them to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 69 69 170 330 570 1150

µtot = 0,1 (lightly oiled)

- Tighten the screws (12) of the housing crosswise to the same torque rates.
EF.V. - Tighten the screw plug with the welded
on positioning pin into the top half of the housing.

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insulated Insulation monitoring

bearings
In the case of electric insulated bearings provided with insulation monitoring, the cable coming out
of the housing must be connected in a professional manner.
According to the type supplied, please follow the assembly instructions given below.
a) The cable is very short and provided with a further cable connector at the end of it.
This cable is ready for connection to the housing.
The bottom half of the housing is provided with the counterpart.
- Plug the cable connector into the counterpart.

Attention!
This connection bypasses the electrical insulation of the bearing.
In the case of electric machines, make sure at least one bearing is electrically insulated.

To check the electrical insulation, interrupt the connection cable
housing. Check the electrical
resistance with a suitable measuring instrument. Make sure that both bearings and the coupling
are electrically insulated.
b) The cable has a free end. In this case the customer has to make the connection.

Attention!
If only one bearing is insulated, the end of the cable must not be earthed.

Any further connection depends on the customer’s requirements related to the insulation
monitoring and can not therefore be described here.

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8.6 Assembly of the Seals
Outboard Side

- Assemble the outboard side seals.
Proceed according to the seal type used:
· Floating labyrinth seal (Type 10) Chapter 8.6.1
· Floating labyrinth seal with dust flinger (Type 11) Chapter 8.6.2
· Floating labyrinth seal with baffle (Type 12) Chapter 8.6.3
· Rigid labyrinth seal (Type 20) Chapter 8.6.4
· Rigid labyrinth seal with dust flinger (Type 21) Chapter 8.6.5
· Rigid labyrinth seal with baffle (Type 22) Chapter 8.6.6

Type
8.6.1 Floating labyrinth seal (Type 10)
10

Warning of injury!
During assembly hold the garter spring ends (49) securely to avoid them suddenly
releasing and causing possible injury!

Check the movement of the floating labyrinth seal on the shaft in the seal area outside the housing.
- Put the garter spring (49) around the shaft and hook both ends into each other.
- Put both halves of the seal (52), (53) in their place on the shaft.
- Put the garter spring (49) into the groove (50).
- Turn the floating labyrinth seal on the shaft.

Attention!
The floating labyrinth seal should turn easily on the shaft. A jammed seal could lead to overheating
during operation and even to shaft wear.
If the floating labyrinth seal jams,

dismantle the seal and

remove the worn parts of the seal carefully, by using emery paper or a plain scraper.

- Dismantle the floating labyrinth seal.

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Maintenance and Inspection

- Apply a uniform layer of sealing compound to the seal surfaces and to the split line surfaces of
both halves of the seal (52), (53).

Please observe the instructions for the use of sealing compound.

Illustration 6: Application of sealing compound to the floating labyrinth seal

- Press the bottom half of the seal (52) against the shaft.
- Place the top half of the seal (53) on the shaft and align both halves of the seal to each other.
- Place the garter spring (49) into the groove (50) and stretch until both ends can be hooked.

54 53 1

49 52 21

Illustration 7: Assembly of the floating labyrinth seal

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- Place in true alignment the split line of the floating labyrinth seal and the split line of the seal
carrier.
- Check that both engraved numbers (56) and (58) on top and bottom halves of the seal carrier
(48), (51) correspond.
- Clean the following parts:
· the seal surfaces of the top (48) and bottom (51) half of the seal carrier (the groove of the
floating labyrinth seal, the flange surfaces)
· the split line surfaces of the top (48) and bottom (51) half of the seal carrier
· the flange surfaces of the housing.
- Apply a uniform layer of sealing compound to:
· the lateral surfaces of the groove at the top (48) and bottom (51) half of the seal carrier
· the flange surfaces of the top (48) and bottom (51) half of the seal carrier
· the split line surfaces of the bottom half of the seal carrier (51).

Please observe the instructions for the use of sealing compound.

Illustration 8: Application of sealing compound to the seal carrier

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Maintenance and Inspection

- Place the top half of the seal carrier (48) on the top half of the seal (53). Press the bottom half
(51) of the seal carrier against it. Push the shaft seal completely into the housing.

48

54

53

Illustration 9: Assembly of the seal carrier

- Place in true alignment the split lines of the seal carrier and the housing.
- Tighten up the screws (55) to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 8 8 8 20 20 20

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Type
8.6.2 Floating labyrinth seal with dust flinger (Type 11)
11
- Assemble the floating labyrinth seal with dust flinger as described in Chapter 8.6.1, Floating
labyrinth seal type 10.
- Place both halves of the dust flinger (69) in front of the shaft seal around the shaft. Loosely
screw in the screws (70).

69 48

e 57

Illustration 10: Clearance between dust flinger and seal carrier

EF..Q - Push the dust flinger (69) into the groove (57) of the seal carrier.
- Set the clearance "e" at the following figure around the whole unit:

maximum longitudinal extension of the shaft in operation + 1 mm

(Parameters indicated in the Technical Documentation of the Installation).
- Tighten up the screws (70) to the following torque rates:

Seal diameter [mm] 80
140 >140

Torque [Nm] 7 18

EF..B, - Push the dust flinger (69) into the groove (57) of the seal carrier.
EF..K, - Set the clearance "e" at 1 mm around the whole unit.
EF..E, - Tighten the screws (70) to the following torque rates:
EF..A
Seal diameter [mm] 80
140 >140

Torque [Nm] 7 18

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Type 8.6.3 Floating labyrinth seal with baffle (Type 12)

12
- Assemble the floating labyrinth seal with baffle as in Chapter 8.6.1, Type 10.
- Apply a uniform layer of sealing compound to the flange surfaces of the top half (66) and
bottom half (68) of the baffle.
- Screw · the top half of the baffle (66) to the top half of the seal carrier (48)
· the bottom half of the baffle (68) to the bottom half of the seal carrier (51).
- Tighten the screws (67) to the following torque rates:

Seal diameter [mm] 80
140 >140

Torque [Nm] 4 10

Type 8.6.4 Rigid labyrinth seal (Type 20)

20
- Check if the engraved numbers (64) and (65) on the bottom half (63) and top half (59) of the rigid
labyrinth seal correspond.
- Clean
· the flange surfaces of the top half (59) and bottom half (63) of the rigid labyrinth seal
· the split line surfaces of the top half (59) and bottom half (63) of the rigid labyrinth seal
· the flange surfaces of the housing.
- Apply a uniform layer of sealing compound to the following parts:
· the flange surfaces of the top half (59) and bottom half (63) of the rigid labyrinth seal
· the split lines of the bottom half (63) of the rigid labyrinth seal.

Please observe the instructions for the use of sealing compound.

Illustration 11: Application of sealing compound to the rigid labyrinth seal

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- Place the top half (59) of the rigid labyrinth seal on the shaft and press slightly the bottom half
(63) of the rigid labyrinth seal from below against it. Lightly push the rigid labyrinth seal
completely into the housing.
- Tighten the screws (61).
- Place in parallel alignment the split line of the rigid labyrinth seal and the split line of the
housing. Press the rigid labyrinth seal slightly from below against the shaft. Adjust the rigid
labyrinth seal in such a way that the clearance "f" between the shaft and the rigid labyrinth seal
at both split lines has the same figure.

1 59

f f

21 63

Illustration 12: Alignment of the rigid labyrinth seal

- Tighten the screws (60) to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 8 8 8 20 20 20

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 Maintenance and Inspection

Type 8.6.5 Rigid labyrinth seal with dust flinger (Type 21)
21
- Assemble the rigid labyrinth seal with dust flinger as indicated in Chapter 8.6.4, Type 20.
- Place both halves of the dust flinger (69) round the shaft, in front of the rigid labyrinth seal.
Mount the screws (70) loose.

69 59

e
62

Illustration 13: Clearance between dust flinger and rigid labyrinth seal

EF..Q - Push the dust flinger (69) into the groove (62) of the rigid labyrinth seal.
- Set the clearance "e" at the following figure around the whole unit:

maximum longitudinal extension of the shaft in operation + 1 mm

(Parameters are indicated in the Technical Documentation of the Installation).
- Tighten the screws (70) to the following torque rates:

Seal diameter [mm] 80
140 >140

Torque [Nm] 7 18

EF..B, - Push the dust flinger (69) into the groove (62) of the rigid labyrinth seal.
EF..K, - Set the clearance "e" at 1 mm around the whole unit.
EF..E, - Tighten the screws (70) to the following torque rates:
EF..A
Seal diameter [mm] 80
140 >140

Torque [Nm] 7 18

Type 8.6.6 Rigid labyrinth seal with baffle (Type 22)

22
- Assemble the rigid labyrinth seal with baffle as described in Chapter 8.6.4.
- Apply a uniform layer of sealing compound to the flange surfaces of the top half (66) and
bottom half (68) of the baffle.
- Screw · the top half of the baffle (66) to the top half (59) of the rigid labyrinth seal.
· the bottom half of the baffle (68) to the bottom half (63) of the rigid labyrinth seal.
- Tighten the screws (67) to the following torque rates:

Seal diameter [mm] 80
140 >140

Torque [Nm] 4 10

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9 Starting Operation after Inspection

- Fit the thermo sensors for:

· temperature measurement of the journal part in the tapped holes (22)
· temperature measurement of the thrust part in the tapped holes (optional).
- Retighten all screw plugs in the tapped holes (22), (24), (27), (29) to the following torque rates:

Screw plug threads G 3/8 G 1/2 G 3/4 G1 G 1 1/4 G 1 1/2 G2 G 2 1/2

Torque [Nm] for plugs 30 40 60 110 160 230 320 500

with injection
moulded
plastic sealing ring

Torque [Nm] for plugs 34 60 85 130 240 300 330 410

with flexible sealing ring

- Check that the top sight glass (5) is tight.

- Retighten the connection holes for oil inlet and oil outlet and the holes for the thrust part oil
supply system (optional). The torque depends on the threaded joints used.
- Carry out a visual check of the assembled bearing.
- Fill up the oil supply system with lubricant. Use the same type of lubricant as indicated on the
type plate.
- Start operating the oil supply system in order to fill up the bearing with lubricant.
- Check
· the way the oil supply system functions ( see also the Technical Documentation of the
Installation).The lubricant quantity at the bearing oil inlet must correspond to the values
indicated in the EDP
calculations.
· that the temperature monitoring equipment functions.

Attention!
· Not enough lubricant leads to temperature rises and thus to damage to the bearing.
· Too much lubricant leads to leakages.

EFT.. - Start operating the cooling water supply system and check its functioning.

The bearing is ready for operation.

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- Supervise the bearing during the trial run ( 5
10 operating hours ).

Pay special attention to:
· the way the oil supply system works (necessary lubricant quantity, lubricant pressure before
entering the bearing)
· bearing temperature
· sliding noises of the shaft seals
· tightness
· occurrence of inadmissible vibrations.

Attention!
If the bearing temperature exceeds the calculated value by 15 K (see the EDP
bearing
calculations) stop the installation immediately. Carry out an inspection of the bearing and find out
the causes.

10 Corrosion Protection for Longer Standstill Periods

If you want to protect the bearing mounted on an installation against corrosion proceed as follows:
- Dismantle the bearing (see Chapter 6).
- Clean the bearing (see Chapter 7).
- Paint or spray the top half of the shell (11), the bottom half of the shell (13) and the shaft with
TECTYL 511.
- Assemble the bearing (see Chapter 8).
- Close all tapped holes with screw plugs.
- Seal the gaps between · shaft seal and housing
· shaft seal and shaft
by using a self
adhesive, permanent tape.
- Remove the top sight glass (5). Spray some anti
corrosive such as TECTYL 511 or VALVOLINE
into the bearing.
- Put a bag of dessicant (silicate gel) inside. The dessicant absorbs the humidity and prevents the
formation of condensation water inside the bearing.
- Close the bearing tight with the top sight glass (5).

In case the standstill period is longer than 1/2 year:

- Repeat the preservation procedures.
- Put a new bag of dessicant into the bearing.

In case the standstill period lasts more years:

- Dismantle the shells.
- Preserve and store the bearing parts.

11 Transport Protection

In case of a machine equipped with slide bearings of type EF:

- Carry out the corrosion protection as described in Chapter 10 and apply enough lubricant on
the working surfaces of the bearing.
- Secure the shaft against thrust and radial movements during transport.

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12 Glossary

Baffle With bearing types 10 and 20 the baffles are assembled externally in front of the shaft
seals. The baffle, made of reinforced polyamide, protects the bearing from dust and
water.

Rigid labyrinth seal The rigid labyrinth seal (type 20) is used with slide bearings type E with high oil
throughput.It corresponds to the protective system IP44 and is made of an aluminium
alloy.
The rigid labyrinth seal is built of two halves, flanged at the housing.The labyrinths that
wipe out the lubricant are arranged into two groups.The first two labyrinths , installed
inside keep back most of the lubricant. Five further labyrinths protect the bearing from
outside.They prevent the lubricant overflow and the ingress of impurities.The overflow
lubricant is collected into a chamber between the both groups of labyrinths.Through
the return bores the lubricant flows back into the bearing.

Spherical seating The spherical seating is a special feature enabling the alignment of the shell in the
housing.The shell is seated on two spherical seatings. The advantages of the spherical
seating are:
· easy at assembly
· good heat transfer from the shell to the housing
· suitable for such applications with high thrust or journal loads.

Dust flinger In the case of bearing types 10 and 20 a light alloy ring is clamped on the shaft in front
of the shaft.This ring fits into a groove in the seal carrier or the rigid labyrinth seal, thus
building a labyrinth. The labyrinth protects the shaft exit against low pressure that could
otherwise " absorb " the lubricant. Low pressure occurs for instance in the case of
rotating discs, such as couplings or cooling discs.

Floating labyrinth The floating labyrinth seal (type 10) in the seal carrier is used as a shaft seal in the case
seal of bearings type E operating under normal conditions. It prevents the lubricant and
lubricant mist coming out and the ingress of impurities. The floating seal has a high
capacity of resistance to wear. It is made of a high
performance, high temperature
stability and electrically insulated plastic material.The floating seal consists of two
halves held together by a garter spring. Both ends of the spring are hooked together. In
the case of slide bearings type EM the floating seal is mounted into a two
piece seal
carrier. The groove allows for radial movement of up to 1 mm. The seal is thus
insensitive to shaft radial displacement or deflection. The sealing effect is produced by
the baffles wiping off the lubricant from the shaft. The lubricant flows back into the
bearing via oil return opening.

Machine seal In the case of the flange mounted bearings, the machine seal reduces the influence of
positive and negative pressure in the machine thus preventing leakages at the inner
seal area. The space between the machine seal and the bearing housing must always
be vented to atmospheric pressure. The size of the gap between shaft and machine
seal influences the sealing effect.

Ó RENK AG Werk Hannover RH
EFZWI
E Version: 1 Juli, 2002 51

Instructions
For Installation and Operation

Slide Bearings TYPE EF

with external oil supply

RH - EFZEI - E - 7.02
Installation and Operation

RENK AKTIENGESELLSCHAFT
Werk Hannover
Weltausstellungsallee 21
D - 30539 Hannover
Telephone: (0511) 8601-0
Telefax: (0511) 8601-266
e-mail: [email protected]
http:\\www.renk.biz

All rights reserved. Copy or reproduction without prior permission of RENK Aktiengesellschaft Hannover
prohibited.

2 RH-EFZEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 EF with external oil supply

Contents

Bearing Coding ...........................................................................................................................................5

General Drawing of the EF Slide Bearing with External Oil Supply ...........................................................7
General Drawing of the Thrust Part with Circular Tilting Pads (RD-Thrust Pads) .....................................9
General Drawing of the Loose Oil Ring ....................................................................................................11
General Drawing of the Floating Labyrinth Seal with Seal Carrier ...........................................................13
General Drawing of the Rigid Labyrinth Seal ...........................................................................................15
General Drawing of the Baffle...................................................................................................................17
General Drawing of the Dust flinger..........................................................................................................19
1 Considerations for Use...........................................................................................................................21
2 Safety Instructions ..................................................................................................................................22
3 Preparatory Work ....................................................................................................................................23
3.1 Tools and equipment..........................................................................................................................23
3.2 Use of lifting equipment......................................................................................................................23
3.3 Dismantling of the bearing .................................................................................................................25
3.3.1 Dismantling of the shaft seal - outboard side .............................................................................25
3.3.2 Dismantling of the housing .........................................................................................................26
3.3.3 Dismantling of the shaft seal - machine-side..............................................................................26
3.4 Cleaning of the bearing ......................................................................................................................27
3.5 Checks ...............................................................................................................................................27
3.6 Assembly of the circular tilting pads (RD-thrust pads).......................................................................28
4 Assembly of the Bearing ........................................................................................................................31
4.1 Assembly of the the machine seal .....................................................................................................31
4.2 Fitting the bottom half of the housing into the machine shield...........................................................32
4.3 Fitting in the bottom half of the shell ..................................................................................................32
4.4 Assembly of the shaft seal - machine-side ........................................................................................33
4.5 Installation of the loose oil ring...........................................................................................................35
4.6 Fitting in the top half of the shell ........................................................................................................36
4.7 Assembly of the top half of the housing .............................................................................................37
5 Assembly of the Seals - Outboard Side ................................................................................................39
5.1 Floating labyrinth seal (Type 10)........................................................................................................39
5.2 Floating labyrinth seal with dust flinger (Type 11) .............................................................................43
5.3 Floating labyrinth seal with baffle ( Type 12) .....................................................................................44
5.4 Rigid labyrinth seal (Type 20) ............................................................................................................44
5.5 Rigid labyrinth seal with dust flinger (Type 21) ..................................................................................46
5.6 Rigid labyrinth seal with baffle (Type 22) ...........................................................................................47

RENK AG Werk Hannover RH-EFZEI-E Version: 1 Juli, 2002 A 3

Installation and Operation

6 Instructions for Assembly of Peripheral Equipment ...........................................................................48

6.1 Assembly of the oil supply equipment................................................................................................48
6.2 Temperature measurement ...............................................................................................................50
6.3 Water supply ......................................................................................................................................50
7 Bearing Insulation ...................................................................................................................................51
8 Operation..................................................................................................................................................51
8.1 Filling up with lubricating oil ...............................................................................................................51
8.2 Trial run ..............................................................................................................................................52
9 Glossary ...................................................................................................................................................53

4 RH-EFZEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 EF with external oil supply

Bearing Coding

RENK AG Werk Hannover RH-EFZEI-E Version: 1 Juli, 2002 A 5

Installation and Operation

n o p q r s
Type Housing Heat Dissipation Shape of Bore and Type of Thrust part Size - Diameter
Lubrication

E F - flange mounted Z - lubrication by oil circulation with C - plain cylindrical bore Q - without thrust part 9 80 D 100
bearing external oil cooling without oil ring (non locating bearing )
11 100 D 125
X - lubrication by oil circulation with B - plain sliding surfaces
L - plain cylindrical bore with
external oil cooling when (locating bearing) 14 125 D 60
loose oil ring
oil throughput is high
Y - two-lobe bore (”lemon bore”) E - taper land faces for one 18 160 D 200
U - circulating pump and natural sense of rotation
without oil ring
cooling (locating bearing) 22 200 D 250
V - four-lobe bore
T - circulating pump and water K - taper land faces for both 28 250 D 315
without oil ring
cooling (finned tubes in senses of rotation
oil sump ) (locating bearing)

A - elastically supported circular

tilting pads (locating bearing)

Example for bearing coding:

n o p q r s
E F Z L K 22-200 Type EF slide bearing with flange-mounted housing, lubrication by
oil circulation with external oil cooling, plain cylindrical bore with loose oil ring,
locating bearing with taper land faces for both senses of rotation, size 22, dia meter 200.

Shaft seals Type 10 - floating labyrinth seal (IP 44)

Type 11 - floating labyrinth seal with dust flinger (IP 54)
Type 12 - floating labyrinth seal with baffle (IP 55)

Type 20 - rigid labyrinth seal (IP 44)

Type 21 - rigid labyrinth seal with dust flinger (IP 54)
Type 22 - rigid labyrinth seal with baffle (IP 55)

6 RH-EFZEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 external oil supply

General Drawing of the

EF Slide Bearing

with external oil supply

RENK AG Werk Hannover RH-EFZE/WI-E Version: 1 Juli, 2002 A 7

 5 6 7 8 9

4
10

11

3 12

13
2
14

15
1
16

17
xxx

x
18
31 xxx

19

30
20

29 21

22

23

24

28 27 26 25
 1 Top half of the housing
2 Hole for positioning pin
3 Positioning pin
4 Connection hole for the oil supply of the thrust part
5 Top sight glass
6 Eye bolt
7 Screw (not included in delivery)
8 Screw
9 Tapped hole ( in the top and bottom halves of the shell, up size 14 )
10 Machine seal
11 Top half of the shell
12 Screw (split line of the housing)
13 Bottom half of the shell
14 Spherical seating
15 Engraved number - shell
16 Spigot
17 Tapped hole
18 Screw (not included in delivery)
19 Screw (split line of the shell)
20 Engraved numbers - housing
21 Bottom half of the housing
22 Tapped hole for temperature measurement of the journal part
23 Oil inlet connection hole
24 Tapped hole for the oil sump temperature measurement
25 Outlet/Inlet cooling water (Type E.T..)
26 Cooler ( Type E.T..)
27 Hexagon head plug (Oil drain plug)
28 Metal tabs ( optional for EFZL. )
29 Oil outlet connection hole
30 Oil outlet pipe with lock nut and lead seal
31 Marking
 external oil supply

General Drawing of the

Thrust Part with Circular Tilting Pads

(RD-Thrust Pads)

RENK AG Werk Hannover RH-RDZE/WI-E Version: 1 Juli, 2002 A 9

37

38

39

40

41

42

43
37 Carrier ring
38 Location groove
39 Shroud ring top half
40 Screw
41 Shroud ring bottom half
42 Circular tilting pad (RD-thrust pad)
43 Anti - Rotation pin
 external oil supply

General Drawing of the

Loose Oil Ring

RENK AG Werk Hannover RH-LSZE/WI-E Version: 1 Juli, 2002 A 11

44

45

46

47
44 Loose Oil Ring
45 Dowel pin
46 Hole
47 Screw
 external oil supply

General Drawing of the

Floating Labyrinth Seal

with Seal Carrier

RENK AG Werk Hannover RH-SSZE/WI-E Version: 1 Juli, 2002 A 13

 Bearing side
48

49
54

53

50

52

51

Outer view
58 55

57

56
48 Seal carrier - top half
49 Garter spring
50 Groove
51 Seal carrier - bottom half
52 Bottom half of the seal
53 Top half of the seal
54 Anti - rotation pin
55 Screw
56 Engraved number
57 Groove ( Type 11 )
58 Engraved number
 external oil supply

General drawing of the

Rigid Labyrinth Seal

RENK AG Werk Hannover RH-KDZE/WI-E Version: 1 Juli, 2002 A 15

 59
60

65

61 (2x)

62

64

63
59 Rigid labyrinth seal - top half
60 Screw
61 Screw (split line)
62 Groove ( Type 21 )
63 Rigid labyrinth seal - bottom part
64 Engraved number
65 Engraved number
 external oil supply

General Drawing of the

Baffle

RENK AG Werk Hannover RH-DSZE/WI-E Version: 1 Juli, 2002 Av 17

 66

67

68
66 Baffle - top half
67 Screw
68 Baffle - bottom half
 external oil supply

General Drawing of the

Dust Flinger

RENK AG Werk Hannover RH-LRZE/WI-E Version: 1 Juli, 2002 A 19

 69

70 (2x)
69 Dust flinger
70 Screw (split line)
 EF with external oil supply

1 Considerations for Use

The instructions for installation and operation are addressed to qualified technical personnel
(fitters, mechanic installers, mechanical engineers).

Read these instructions carefully before starting assembly.

Slide bearings of type EF are almost universally used in the engineering industry. Therefore it is
not possible to provide detailed information on all possible types and range of applications for
these bearing types. For instance, the position of the connection points for supply and monitoring
equipment is determined by the place of application ( in the following called " installation " ). Please
keep ready the guidelines with the technical documentation before starting assembly and operation
of the slide bearings.

Additional technical documentation with detailed information is supplied in the case of special
design bearings. Please contact RENK Export or Domestic Department for supplementary
information on bearings. Please indicate the bearing coding and the full reference number, too.

Following indications should be observed when reading these instructions.

Safety instructions are marked as follows:

Danger!
Warning of dangers for personnel.
Example: Warning of injury

Attention!
Warning of damage for the bearing or installation.

Useful recommendations and additional information are framed.

EF...Q This is how chapters, instructions or recommendations are marked when referring to a single type
or size of a bearing.
Example: Slide bearing type EF without thrust part ( non-locating bearing )

- Instruction follows.
Beginning of an enumeration.
( ) This is how the different parts of a bearing as described in the general drawings ( numbers )
are marked in the text.

− Use the enclosed check-list before starting assembly or operation. Copies available on request.
The check list provides the experienced mechanical fitters of RENK bearings with the
necessary instructions for installation and operation.

RENK AG Werk Hannover RH-EFZEI-E Version: 1 Juli, 2002 A 21

Installation and Operation

2 Safety Instructions

Danger!
The maintenance and inspection of the slide bearings should be carried out by:
persons nominated by the safety representative
persons correspondingly trained and instructed
persons with knowledge on appropriate standards, regulations and accident
prevention rules
persons with knowledge on first-aid measures and local rescue centers.

Warning of injury!
Before starting work on the bearing:
- Switch off the installation.
- Make sure the installation is not in operation.
Never lift or transport machines, etc.by the bearing eye bolts. These are only intended
for assembly and dismantling of the bearing !

Warning of injury!
Do not grab such heavy bearing parts as the housing during assembly or dismantling
work. This could result in bruising or injury to hands !

Attention!
All metal parts of a slide bearing consisting of top and bottom part such as the housing, shells,
shaft seals are marked by engraved numbers. Fit together only the parts with the same number.

Attention!
In case • the admissible bearing temperature exceeds by 15 K,
• inadmissible vibrations occur,
• unusual noises or odours are noticed,
monitoring equipment triggers alarm,
shut down the installation and inform the maintenance personnel in charge.

Attention!
Do not operate the bearing below the transition speed values indicated in the bearing calculation,
thus avoiding inadmissible operating conditions, which could lead to damage to the bearing.

Attention!
Please observe our leaflet Technical Information No. 85 which refers to various sealing compounds
for extended technical applications.

22 RH-EFZEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 EF with external oil supply

3 Preparatory Work

3.1 Tools and equipment

− Following tools and equipment are necessary:
• Allan key set
• Wrenching key set
• Open-jawed spanner set
• Feeler gauges ( up 0,05 mm )
• Caliper gauge
• Emery paper, plain scraper
• Oil stone
• Lifting equipment
• Permanent sealing compound
• Clean (close weave) rags
• Oil with the correct viscosity ( see bearing type plate )
• Detergents
• Liquid screw locking compound ( e.g. LOCTITE 242 )
• Liquid sealing compound and Teflon-tape

3.2 Use of lifting equipment

Warning of injury!

Before transport or lifting, check if the eye bolts are tight ! Insecure eye bolts could
result in bearing becoming loose.
Before moving the bearing by the eye bolts make sure that the split line screws are
tightened, otherwise the bottom half of the bearing could become detached.
Make sure that the eye bolts are not exposed to bending stress, otherwise the bolts
could break.

Follow exactly the instructions for the use of lifting equipment.

− Use lifting equipment for assembly or transport of the following items:

Transport/Assembly of: Use lifting equipment for the following bearing sizes

Whole bearing unit 9-28

Top half of the housing 14-28

Bottom half of the housing 11-28

Shells 14-28

RENK AG Werk Hannover RH-EFZEI-E Version: 1 Juli, 2002 A 23

Installation and Operation

− Following steps are to be observed before using the lifting equipment:

Whole bearing unit

− Check if the screws are tight (12):

Bearing size 9 11 14 18 22 28

Torque [Nm] 69 69 170 330 570 1150

− Check if the eye bolts (6) are tight.

− Connect the lifting equipment to the eye bolts (6).

Top half of the housing

− Check if the eye bolts (6) are tight.
− Connect the lifting devices to the eye bolts (6).

Bottom half of the housing

− Screw two eye bolts (6) with suitable threads tight into the cross-placed opposite tapped holes
(17).

Bearing size 9 11 14 18 22 28

Tapped hole M 12 M 12 M 16 M 20 M 24 M 30

− Connect the lifting equipment to the eye bolts (6).

Shells
− Screw two eye bolts or screw hooks with suitable threads tight into the tapped holes (9):

Bearing size 14 18 22 28

Tapped hole M8 M 12 M 12 M 16

− Connect the lifting equipment to the eye bolts or to the screw hooks.

24 RH-EFZEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 EF with external oil supply

3.3 Dismantling of the bearing

Attention
Make sure that the work place and the parts to be assembled are clean. Contamination and
damage to the bearing, especially to the working surfaces, have a negative influence on the
operating quality and could lead to premature failure.

3.3.1 Dismantling of the shaft seal - outboard side

− Dismantle the shaft seals of the bearing. Proceed according to the sealing type:

Type Floating labyrinth seal (Type 10)

10 Floating labyrinth seal with dust flinger (Type 11)
Type
− Loosen and remove all screws (55).
11
− Simultaneously take away in axial direction both top half (48) and bottom half (51) of the seal
carrier from the housing.
− Lift off the top half of the seal carrier (48) and take out the floating labyrinth seal from the bottom
half of the seal carrier (51).
− Remove the protective cardboard (for transport protection) from the floating labyrinth seal.
− Proceed as indicated for sizes • 9-11
•14-28
Size − Take hold of the floating labyrinth seal with both hands. Press out the protective cardboard with
9 -11 both thumbs.
Size − Take both halves of the seal (52), (53) by the split line. Pull both halves apart, till you can press
14-18 out the protective cardboard. Remove carefully by pressing along the edge of the split line.

Warning of injury!
During dismantling of the floating labyrinth seal hold on tight to the tensioned garter
spring (49) which otherwise could bounce back and lead to injury.

− Take both seal halves (52), (53) and pull them apart by approximately 20 mm.
− Open the garter spring (49).

Type Floating labyrinth seal with baffle ( Type 12 ):

12
− Disconnect the top half of the baffle (66) and the bottom (68). To do so, loosen the screws (67).
− Further proceed as in the case of type 10 and 11 seal.

Type Rigid labyrinth seal (type 20)

20 Rigid labyrinth seal with dust flinger (type 21)
Type − Untighten all screws (60) and remove them.
21 − Simultaneously remove in axial direction both top and bottom (59), (63) halves of the rigid
labyrinth seal.
− Remove the screws (61).
− Separate the top half of the rigid labyrinth seal (59) from the bottom half (63) and take out the
protective cardboard (used for safe transport).

Type Rigid labyrinth seal with baffle (type 22)

22
− Separate the top and bottom half (66), (68) of the baffle, by untightening the screws (67).
− Further proceed as in the case of types 20 and 21.

RENK AG Werk Hannover RH-EFZEI-E Version: 1 Juli, 2002 A 25

 Installation and Operation

3.3.2 Dismantling of the housing

EF.V. − Unscrew the screw plug with the welded-on positioning pin.

− Unscrew the screws (12) and lift the top half of the housing (1).
− Take out both top (11) and bottom (13) halves of the shell from the bottom half of the housing
(21).

Attention!
Do not damage the thrust and radial working surfaces!

− Unscrew the screws (19) and separate the top and bottom halves of the shell (11), (13) without
using any tools or other devices.

Attention!
If the bottom half of the shell (13) is provided with metal tabs (28) do not remove them. They
regulate the oil level in the oil pockets.

EFT..
The cooler (26) is already assembled and does not have to be removed for cleaning purposes.

3.3.3 Dismantling of the shaft seal - machine-side

The machine side seal is of Type 10, floating labyrinth seal.

− Remove the floating labyrinth seal from the bottom half of the housing.
− Notice the anti-rotation pin at the split line of the bottom half of the housing.
− Remove the protective cardboard (for transport protection) from the floating labyrinth seal.
− Proceed as indicated for sizes • 9-11
•14-28

Size − Take hold of the floating labyrinth seal with both hands. Press out the protective cardboard with
9 -11 both thumbs.

Size − Take both halves of the seal (52), (53) by the split line. Pull both halves apart, till you can press
14-18 out the protective cardboard. Remove carefully by pressing along the edge of the split line.

Warning of injury!
During dismantling of the floating labyrinth seal hold on tight to the tensioned garter
spring (49) which otherwise could bounce back and lead to injury.

− Take both seal halves (52), (53) and pull them apart by approximately 20 mm.
− Open the garter spring (49).

26 RH-EFZEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 EF with external oil supply

3.4 Cleaning of the bearing

Attention!
Use only non-aggressive detergents, such as for instance:
VALVOLINE 150.
Alcaline cleaning compounds (pH-value 6 to 9, short reaction time).

Warning of injury!
Please observe the instructions for the use of the detergents.

Attention!
Never use cleaning wool or fibrous cloth. Residues of such materials left in the bearing could lead
to excessive temperatures.

− Clean the following parts thoroughly, to remove all residues of preservation :

• inside the top half of the housing (1)
• inside the bottom half of the housing (21)
• all plain parts of the top and bottom half of the housing (1), (21)
• top half of the shell (11)
• bottom half of the shell (13)
• sealing surfaces of the top (48) and bottom (51) half of the seal carrier or of the rigid labyrinth
seal

EF.L. • loose oil ring (44).

3.5 Checks

− Please check if there is any visible damage. Check the split line and the working surfaces in
particular.

EF.L. The loose oil ring (44) should show absolutely no burrs or have no shoulders.

Insulated − Check the insulating layer of the spherical seating (14).

Bearings

− If necessary, change the damaged parts.

RENK AG Werk Hannover RH-EFZEI-E Version: 1 Juli, 2002 A 27

 Installation and Operation

EF..A 3.6 Assembly of the circular tilting pads (RD-thrust pads)

− Clean both top (39) and bottom (41) halves of the shroud ring and all RD-thrust pads (42).
Proceed as described under chapter 3.4 (Cleaning of the bearing).

Bearing size Diameter Number of RD-thrust pads per bearing [Pieces]

80 14
9 90 16
100 20
100 16
11 110 18
125 22
125 18
14 140 20
160 24
160 18
18 180 20
200 24
200 18
22 225 20
250 24
250 18
28 280 20
300 24

− Check if the parts show any visible damage.

Carry out the assembly of both thrust parts of the top (11) and bottom (13) half of the shell
according to the following instructions:
One RD-thrust pad on both sides of the top half of the shell has a bore for the insertion of a thermo
sensor (thrust part temperature measurement).

28 RH-EFZEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 EF with external oil supply

To mount the RD-thrust pad into the correct position proceed as follows:

− Find the position of the location groove (38) on the top half of the shroud ring (39). Insert the
RD-thrust pad (42) with the anti-rotation pin (43) into the corresponding thrust pad location hole
(37).
− Insert all other RD-thrust pads (42) into the corresponding thrust pad holes (37)
of the top and bottom half of the shell (11), (13).

42

37

Illustration 1: Assembly of the RD-thrust pads

− Place the top half of the shroud ring (39) into the the top half of the shell (11) by inserting the
anti-rotation pin (43) into the location hole (38). Match the split line of the top half of the shell
(11) with the split line of the top half of the shroud ring (39) in true alignment.

38

39

43

42

Illustration 2: Assembly of the shroud ring

RENK AG Werk Hannover RH-EFZEI-E Version: 1 Juli, 2002 A 29

Installation and Operation

− Tighten the screws (40) to the following torque rates:

Bearing size 9 11 14 18 22 28

Tapped hole M4 M4 M5 M6 M8 M 10

Torque [Nm] 1,4 1,4 2,7 8 20 40

− Place the bottom half of the shroud ring (41) into the bottom half of the shell (13). Match the
corresponding split lines in true alignment. Tighten the screws (40) to the same torque rates as
specified for the top half of the shell (11).
− Check the mobility of all RD-thrust pads (42).
If the RD-thrust pads jam, realign the top (39) and bottom half (41) of the shroud ring.

Attention!
Insufficient mobility of the RD-thrust pads will cause damage of the bearing.

Both top and bottom halves of the shells are prepared for assembly.

30 RH-EFZEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 EF with external oil supply

4 Assembly of the Bearing

Attention!
Remove all impurities or other objects such as screws, nuts, etc. from inside the bearing.If left
inside they could lead to damage to the bearing. Cover up the opened bearing during work breaks.

Attention!
Carry out all assembly operations without making use of force.

Attention!
Secure all screws of the housing, at the split line and flange with a liquid screw locking compound
(e.g. LOCTITE 242).

4.1 Assembly of the the machine seal

Before assembly of the bearing screw the split and non-split machine seal (10) into the machine
shield. The non-split machine seal must be assembled before starting the assembly of the shaft.
− Fit the machine seal with the recess onto the machine shield.
− In the case of a split machine seal insert the split line screws and tighten them hand tight.
− Tighten the screws (7) to the following torque rates:

Bearing size 9 11 14 18 22 28

Tapped hole M6 M6 M6 M8 M8 M8

Torque [Nm] 8 8 8 20 20 20

RENK AG Werk Hannover RH-EFZEI-E Version: 1 Juli, 2002 A 31

 Installation and Operation

4.2 Fitting the bottom half of the housing into the machine shield

Attention!
The lifting equipment should not come to contact with the seal and working surfaces of the shaft.

− Lift the shaft high enough to give room for the assembly operations.
− Protect the shaft against unintended movement.
− Place the bottom half of the housing with the spigot (16) into the mounting recess of the
machine shield.
− Tighten the flange screws to the following torque rates.

EF..A − In case the bearings type EF are operating under high axial loads tighten the third flange screw
mounted on the inner part of the machine shield into the bottom half of the housing to the
following torque rates.

− Use only 8.8 quality screws.

Bearing size 9 11 14 18 22 28

Suitable flange screws M 10 M 12 M 16 M 20 M 24 M 30

Torque [Nm] for µ tot 69 69 170 330 570 1150

(lightly oiled)

4.3 Fitting in the bottom half of the shell

EF..E Attention!
Mounting the bottom half of the shell (not marked with an arrow) correctly will ease the assembly of
the top half shell (marked with an arrow) (see chapter 4.6).

− Apply some lubricant to the spherical seating (14) in the bottom half of the housing (21) and to
the working surfaces of the shaft. Use the same type of lubricant as indicated for bearing
operation (see type plate ).
− Place the bottom half of the shell (13) on the working surface of the shaft. Turn the bottom half
of the shell (13) into the bottom half of the housing (21) with the split line surfaces of both halves
in true alignment.

In case the bottom half of the shell doesn`t turn in easily, check the position of the shaft and the
alignment of the housing

EF..B, Attention!
EF..K These operations should be carried out most carefully. The thrust parts of the bottom shell must
EF..E not be damaged.
EF..A
− Lower down the shaft till it sits on the bottom half of the shell (13).

32 RH-EFZEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 EF with external oil supply

4.4 Assembly of the shaft seal - machine-side

The machine-side shaft seal is, as standard, a floating labyrinth seal. The integrated seal groove is
in the top and bottom halves of the housing.

Warning of injury!
During assembly hold the garter spring ends securely to avoid them suddenly
releasing and causing possible injury !

Check the movement of the floating labyrinth seal on the shaft in the seal area outside the housing.
− Put the garter spring (49) around the shaft and hook both ends into each other.
− Put both halves of the seal (52),(53) in their place on the shaft.
− Put the garter spring (49) into the groove (50).
− Turn the floating labyrinth seal on the shaft.

Attention!
The floating labyrinth seal should turn easily on the shaft. A jammed seal could lead to overheating
during operation and even to shaft wear.
If the floating labyrinth seal jams,
- dismantle the seal and
- remove the worn parts of the seal carefully, by using emery paper or a plain scraper.

− Dismantle the floating labyrinth seal.

− Apply sealing compound to the guide surfaces of the integrated seal groove in the bottom half of
the housing.

Illustration 3: Application of sealing compound to the integrated seal groove

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Installation and Operation

− Apply a uniform layer of sealing compound to the guide surfaces and to the split line surfaces of
both halves of the seal (52), (53).

Illustration 4: Application of sealing compound to the floating labyrinth seal

Please observe the instructions for the use of sealing compound.

− Place the bottom half of the seal (52) with the labyrinths onto the shaft.
− The oil return holes at the bearing side must be clear and open.
− Turn the seal in opposite direction from the anti-rotation pin into the groove of the housing until
the split lines of the bottom half of the housing and the bottom half of the seal match each other.
− Remove the residue of sealing compound.
− Push the garter spring into the integrated seal groove between the bottom half of the housing
and the seal until both ends jut out from the split line.
− Place the top half of the seal with the cam facing the inside of the bearing on the bottom half of
the seal.
− Stretch the garter spring till both ends can be hooked.

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 EF with external oil supply

EF.L. 4.5 Installation of the loose oil ring

− Open both split lines of the loose oil ring (44) by untightening and removing the screws (47).
Separate both halves of the loose oil ring (44) carefully without using any tools or other devices.

I II

44

44 44

47

Illustration 5: Opening of the loose oil ring

− Place both halves of the loose oil ring into the shell groove around the shaft. Press the
positioning pin (45) of each split line into the corresponding hole (46).
− Adjust both halves of the loose oil ring till the split lines match each other.

21
45

44

44 13

Illustration 6: Installation of the loose oil ring

− Tighten the screws (47) to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 1,4 1,4 1,4 2,7 2,7 2,7

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 Installation and Operation

4.6 Fitting in the top half of the shell

− Apply some lubricant to the working surfaces of the shaft. Use the same type of lubricant as
indicated for bearing operation (see type plate).
− Check if the engraved number (15) on the bottom half of the shell corresponds with the
engraved number (15) on the top half of the shell.
− Place the top half of the shell (11) on the shaft; both engraved numbers (15) should be on one
side.

Attention!
An incorrectly placed shell could jam the shaft thus leading to the damage of both shaft and
bearing.

EF..B, Attention!
EF..K, Place the top half of the shell carefully on the shaft. The thrust parts of the top half of the shell must
EF..E, not be damaged.
EF..A

insulated In the case of bearings arranged for insulation monitoring, connect the black cable for insulation
bearings monitoring to the shell.
According to the bearing type, there are two possibilities of connection.
1. The black cable is provided with a cable connector.
− Plug the cable with the cable connector into the counterpart available on the top of the shell.
− Lead the cable through the cable gland in the bottom half of the housing and out of the bearing.
− Tighten the cable gland oil-tight.
2. The black cable is provided with an eyelet.
− Fasten the cable with the eyelet to the split line of the shell, by using one of the shell joint bolts.
− Lead the cable through the cable gland in the bottom half of the housing and out of the bearing.
− Tighten the cable gland oil-tight.

− Tighten up the screw (19) at the split line of the shell to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 8 8 20 69 69 170

− Check the split line of the shell by using a feeler gauge. The split line gap should be less than
0,05 mm. If the split line is greater than this, dismantle both top (11) and bottom (13) halves of
the shell. Rework the split line surfaces of the top (11) and bottom (13) half of the shell with an
oil stone.
EF.L. − Check the mobility of the loose oil ring (44).

Marine A guide bush in the top half of the shell secures the function of the loose oil ring.
bearings
− Check the mobility of the loose oil ring (44) in the guide bush.

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 EF with external oil supply

EF..E Shells with taper land faces suitable only for one direction of rotation are marked with an arrow on
the top half shell, which indicates the sense of rotation of the shaft.
The arrow indicates the allowed direction of shaft rotation after completion of the bearing assembly.
− Before mounting the top half of the housing check that the proposed direction of rotation of the
shaft corresponds to the direction indicated by the arrow on the top half of the shell.
− If the directions match, continue the assembly of the bearing.
− If the directions do not match, the shell must be disassembled, re-aligned and mounted again.

Attention!
A wrongly placed shell, without observance of the direction of rotation of the shaft, impairs the
operational safety of the bearing.

4.7 Assembly of the top half of the housing

− Check the true alignment of the split lines of the shell (11), (13) and bottom (21) half of the
housing.

EF.C. The positioning pin (3) in the top half of the housing fits in the corresponding hole (2) in the shell.
EF.L.
EF.Y.
− Check if the engraved numbers (20) on the top and bottom halves of the housing correspond.
− Clean the split line surfaces of the top and bottom halves of the housing.
− Apply sealing compound over the whole surface of the split line of the bottom half (21) of the
housing.

Please observe the instructions for the use of sealing compound.

− Place the top half of the housing carefully into the machine shield, without touching the seals or
the shell.
− Lower the top half of the housing (1) vertically on the bottom half of the housing (21). Lower the
top half of the housing (1) till the split line of the housing is not visible any more.
− Gently hit the bottom half of the housing (21) with a nylon hammer, thus ensuring the alignment
of the spherical seating.
− Insert the screws (12) at the split line of the housing. Tighten them hand-tight.
− Insert the screws (8). Tighten them to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 69 69 170 330 570 1150

− Insert the screws (12) at the split line of the housing. Tighten them crosswise to the same
torque rates.

EF.V. − Tighten the screw plug with the welded-on positioning pin into the top half of the housing (1).

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 Installation and Operation

insulated Insulation monitoring

bearings
In the case of electric insulated bearings provided with insulation monitoring, the cable coming out
of the housing must be connected in a professional manner.
According to the type supplied, please follow the assembly instructions given below.
a) The cable is very short and provided with a further cable connector at the end of it.
This cable is ready for connection to the housing.
The bottom half of the housing is provided with the counterpart.
− Plug the cable connector into the counterpart.

Attention!
This connection bypasses the electrical insulation of the bearing.
In the case of electric machines, make sure at least one bearing is electrically insulated.

To check the electrical insulation, interrupt the connection cable - housing. Check the electrical
resistance with a suitable measuring instrument. Make sure that both bearings and the coupling
are electrically insulated.
b) The cable has a free end. In this case the customer has to make the connection.

Attention!
If only one bearing is insulated, the end of the cable must not be earthed.

Any further connection depends on the customer’s requirements related to the insulation
monitoring and can not therefore be described here.

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 EF with external oil supply

5 Assembly of the Seals - Outboard Side

− Assemble the outboard side seals.

Proceed according to the seal type used.
• Floating labyrinth seal (Type 10) Chapter 5.1
• Floating labyrinth seal with dust flinger (Type 11) Chapter 5.2
• Floating labyrinth seal with baffle (Type 12) Chapter 5.3
• Rigid labyrinth seal (Type 20) Chapter 5.4
• Rigid labyrinth seal with dust flinger (Type 21) Chapter 5.5
• Rigid labyrinth seal with baffle (Type 22) Chapter 5.6

Type
10 5.1 Floating labyrinth seal (Type 10)

Warning of injury!
During assembly hold the garter spring ends securely to avoid them suddenly
releasing and causing possible injury !

Check the movement of the floating labyrinth seal on the shaft.

− Put the garter spring (49) around the shaft and hook both ends into each other.
− Put both halves of the seal (52),(53) in their place on the shaft.
− Put the garter spring (49) into the groove (50).
− Turn the floating labyrinth seal on the shaft.

Attention!
The floating labyrinth seal should turn easily on the shaft. A jammed seal could lead to overheating
during operation and even to shaft wear.
If the floating labyrinth seal jams,
- dismantle the seal and
- remove the worn parts of the seal carefully, by using emery paper or a plain scraper.

− Dismantle the floating labyrinth seal.

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Installation and Operation

− Apply a uniform layer of sealing compound to the guide surfaces and to the split line surfaces of
both halves of the seal (52), (53).

Please observe the instructions for the use of sealing compound.

Illustration 7: Application of sealing compound to the floating labyrinth seal

− Press the bottom half of the seal (52) against the shaft.
− Place the top half of the seal (53) on the shaft and align both halves of the seal to each other.
− Place the garter spring (49) into the groove (50) and stretch until both ends can be hooked.

54 53 1

49 52 21

Illustration 8: Assembly of the floating labyrinth seal

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 EF with external oil supply

− Place in true alignment the split line of the floating labyrinth seal and the split line of the seal
carrier.
− Check that both engraved numbers (56) and (58) on top and bottom halves of the seal carrier
(48), (51) correspond.
− Clean the following parts:
• the seal surfaces of the top (48) and bottom (51) half of the seal carrier (the groove of the
floating labyrinth seal, the flange surfaces)
• the split line surfaces of the top (48) and bottom half (51) of the seal carrier
• the flange surfaces of the housing.

− Apply a uniform layer of sealing compound to:

• the lateral surfaces of the groove at the top (48) and bottom half (51) of the seal carrier
• the flange surfaces of the top (48) and bottom (51) half of the seal carrier
• the split line surfaces of the bottom half of the seal carrier (51).

Please observe the instructions for the use of sealing compound.

Illustration 9: Application of sealing compound to the seal carrier

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Installation and Operation

− Place the top half of the seal carrier (48) on the top half of the seal (53). Press the bottom half
(51) of the seal carrier against it. Push the shaft seal completely into the housing.

48

54

53

Illustration 10 Assembly of the seal carrier

− Place in true alignment the split lines of the seal carrier and the housing.
− Tighten up the screws (55) to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 8 8 8 20 20 20

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 EF with external oil supply

Type11
5.2 Floating labyrinth seal with dust flinger (Type 11)

− Assemble the floating labyrinth seal with dust flinger as described in Chapter 5.1, Floating
labyrinth seal type 10.
− Place both halves of the dust flinger (69) in front of the shaft seal around the shaft. Loosely
screw in the screws (70) of the flinger.

69 48

e 57

Illustration 11: Clearance between dust flinger and seal carrier

EF..Q − Push the dust flinger (69) into the groove (57) of the seal carrier.
− Set the clearance "e" at the following figure around the whole unit:

maximum longitudinal extension of the shaft in operation + 1 mm

(Parameters indicated in the Technical Documentation of the Installation).

− Tighten up both screws (70) to the following torque rates:

Seal diameter [mm] 80-140 >140

Torque [Nm] 7 18

EF..B, − Push the dust flinger (69) into the groove (57) of the seal carrier.
EF..K, − Set the clearance "e"at 1 mm around the whole unit.
EF..E, − Tighten both screws (70) to the following torque rates:
EF..A
Seal diameter [mm] 80-140 >140

Torque [Nm] 7 18

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 Installation and Operation

Type
5.3 Floating labyrinth seal with baffle ( Type 12)
12
− Assemble the floating labyrinth seal with baffle as described in Chapter 5.1, type10.
− Apply a uniform layer of sealing compound to the flange surfaces of the top half (66) and bottom
half (68) of the baffle.
− Screw • the top half of the baffle (66) to top half of the seal carrier (48)
• the bottom half of the baffle (68) to bottom half of the seal carrier (51).
− Tighten the screws (67) to the following torque rates:

Seal diameter [mm] 80-140 >140

Torque [Nm] 4 10

Type 5.4 Rigid labyrinth seal (Type 20)

20
− Check if the engraved numbers (64) and (65) on the bottom half (63) and top half (59) of the
rigid labyrinth seal correspond.
− Clean
• the flange surfaces of the top half (59) and bottom half (63) of the rigid labyrinth seal
• the split line surfaces of the top half (59) and bottom half (63) of the rigid labyrinth seal
• the flange surfaces of the housing.

− Apply a uniform layer of sealing compound to the following parts:

• the flange surfaces of the top (59) and bottom half (63) of the rigid labyrinth seal
• the split lines of the bottom half (63) of the rigid labyrinth seal.

Illustration 12: Application of sealing compound to the rigid labyrinth seal

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 EF with external oil supply

− Place the top half (59) of the rigid labyrinth seal on the shaft and press slightly the bottom half (63)
of the rigid labyrinth seal from below against it. Lightly push the rigid labyrinth seal completely into
the housing.
− Tighten the screws (61) at the split line of the labyrinth seal.
− Place in parallel alignment the split line of the rigid labyrinth seal and the split line of the housing.
Press the rigid labyrinth seal slightly from below against the shaft. Adjust the rigid labyrinth seal in
such a way that the clearance "f" between the shaft and the rigid labyrinth seal at both split lines
has the same figure.

1 59

f f

21 63

Illustration 13: Alignment of the rigid labyrinth seal

− Tighten the screws (60) to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 8 8 8 20 20 20

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 Installation and Operation

Type 5.5 Rigid labyrinth seal with dust flinger (Type 21)
21
− Assemble the rigid labyrinth seal with dust flinger as described in Chapter 5.4, type 20.
− Place both halves of the dust flinger (69) round the shaft, in front of the rigid labyrinth seal.
Mount both screws (70) loose.

69 59

e
62

Illustration 14: Clearance between dust flinger and rigid labyrinth seal

EF..Q − Push the dust flinger (69) into the groove (62) of the rigid labyrinth seal.
− Set the clearance "e" at the following figure around the whole unit.

maximum longitudinal extension of the shaft in operation + 1 mm

(Parameters are indicated in the Technical Documentation of the Installation).

− Tighten both screws (70) to the following torque rates:

Seal diameter [mm] 80-140 >140

Torque [Nm] 7 18

− Push the dust flinger (69) into the groove (62) of the rigid labyrinth seal.
EF..B,
− Set the clearance "e" at 1 mm around the whole unit.
EF..K,
EF..E, − Tighten both screws (70) to the following torque rates:
EF..A
Seal diameter [mm] 80-140 >140

Torque [Nm] 7 18

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 EF with external oil supply

Type 5.6 Rigid labyrinth seal with baffle (Type 22)

22
− Assemble the rigid seal with baffle as described in Chapter 5.4, type 20.
− Apply a uniform layer of sealing compound to the flange surfaces of the top half (66) and bottom
half (68) of the baffle.
− Screw
• the top half of the baffle (66) to the top half (59) of the rigid labyrinth seal
• the bottom half of the baffle (68) to the bottom half (63) of the rigid labyrinth seal.

− Tighten the screws (67) to the following torque rates:

Seal diameter [mm] 80-140 >140

Torque [Nm] 4 10

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Installation and Operation

6 Instructions for Assembly of Peripheral Equipment

6.1 Assembly of the oil supply equipment

The oil supply equipment together with the pressure, temperature and flow measuring instruments
are usually provided by the user. The oil quantity and viscosity necessary for the operation of the
bearing are specified in the bearing calculations. This manual contains only indications on the
connection points with the bearing. The connection bores for the oil inlets and outlets are on both
lateral sides of the bearing, closed with screw plugs. Remove only those plugs where pipes are to
be connected.

Connection conditions

Pipelines Flow speed Indications

Inlet Precision steel pipe about 1,5 m/s Place the throttle valve in the inlet
DIN 2391 pipeline directly in front of the bearing

Steel pipe DIN 2448

Outlet Steel pipe DIN 2448 max. 0,15 m/s • 15° inclination

• if 15° inclination is not possible

enlarge correspondingly the cross
sections of the pipeline directly
behind the bearing.

Too low inclination or / and too small

cross-section lead to oil back
pressure in the bearing.
Leakage or overflowing are the
consequences.

− Before starting assembly pickle all pipes which • have been welded
• have been bent hot
• are contamined and rusty inside.

Warning of injury!
Please observe the instructions for the use of the pickling fluid. Wear rubber
gloves, rubber apron, rubber boots and safety glasses.

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 EF with external oil supply

Rinsing of the oil circuit

− Rinse the whole oil circuit to remove all impurities. The bearing must not be connected to the
oil circuit during rinsing operations. The rinsing should be done before connecting the oil
supply to the bearing or the bearing should be disconnected from the oil circuit. If this is not
possible, dismantle the top half of the housing and remove the shells.

To avoid damage to the fittings:

− Remove all measuring and switching fittings.
− Close all connections (see also the Technical Documentation of the Installation).
− Fill up the oil supply system with lubricant. Use the type with the viscosity indicated on the
bearing type plate.
− Start operating the oil supply system. Collect the first charge of high contamined oil separately.
Continue rinsing until the lubricant contains no impurities.
− Drain off the oil supply system completely. Clean the oil tank and the filters.

Warning of environmental pollution!

Please observe the instructions for the use of the lubricant. The manufacturer could provide
information on waste oil disposal.

− Assemble all fittings.

Oil inlet
− Connect the inlet pipe to the tapped hole (23) for the oil inlet. Seal with Teflon tape or liquid
sealing compound.
− Depending on the bearing size, the tapped hole has the following threads:

Bearing size 9 11 14 18 22 28

Tapped hole / G 3/8 G 3/8 G 3/8 G 1/2 G 3/4 G 3/4

Oil inlet (23)

If the bearing calculation specifies a separate supply source for the thrust parts:
− connect the inlet pipes to the tapped hole of the thrust part supply (4) on the lateral side of the
bearing. Seal with Teflon tape or liquid sealing compound.

RENK AG Werk Hannover RH-EFZEI-E Version: 1 Juli, 2002 A 49

 Installation and Operation

Oil outlet
EFZ.., − Apply sealing compound (i.e. Loctite 572) to the thread of the oil outlet.
EFX.. − Screw the oil outlet with special nut and lead sealing ring (30) into the oil outlet connection hole
(29).
− Tighten the special nut with the lead sealing ring.
− Connect the oil outlet pipe to the flange.
− Depending on the bearing size the connection hole for the oil outlet (29) has the following
standard threads (larger threads are possible):

Bearing size 9 11 14 18 22 28

Tapped hole for oil G 1 1/4 G 1 1/4 G 1 1/2 G 1 1/2 G2 G 2 1/2

outlet (29)

EF.L. − Apply sealing compound (i.e. Loctite 572) to the thread of the oil outlet.
− Screw the oil outlet with special nut and lead sealing ring (30) into the corresponding hole (29)
with the marking (31) at top dead centre. Tighten the special nut with the lead sealing ring. The
spillover oil weir then ensures the minimum oil level for the emergency lubrication by means of
the loose oil ring. Connect the oil outlet pipe to the flange.

EFU.., − Screw in the outlet pipe to the selected oil sump temperature measurement connection hole
EFT.. (24) and seal with Teflon tape or liquid sealing compound.

6.2 Temperature measurement

− Fix suitable thermo sensors:

• into one of the tapped holes (22) for temperature measurements of the journal parts
• into one of the tapped holes (24) for temperature measurements of the oil sump
• into one of the tapped holes (optional) for temperature measurement of the thrust parts.

Proceed as follows:
− Take out the screw plugs from the connection holes.
− Place the thermo sensor into the bore by using Teflon tape or sealing compound.
− Connect the thermo sensor at the temperature monitoring equipment of the installation
(see the Technical Documentation of the Installation for connecting and adjustment).

EFT.. 6.3 Water supply

Following requirements should be observed before connecting the cooler (26):

• water velocity of maximum 1,5 m/s in the cooling water inlet
• water pressure of maximum 5 bar
• adjusting tap on inlet
• outlet of cooling water is under no pressure.

The direction of the cooling water passage in the cooler (26) is arbitrary.

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 EF with external oil supply

7 Bearing Insulation

These bearings are delivered insulated. The electrical insulation is assured by:
• plastic coating of the spherical seatings (14)
• shaft seals made of non-conducting materials
• insulated positioning pin (3)
• insulated screwed connections for thermometers.

It is not necessary to insulate the pipelines.

− Mark the insulated bearing with the delivered plate "Insulated shells". Install the plate in a visible
place by using two grooved drive studs.

8 Operation

8.1 Filling up with lubricating oil

Attention!
Make sure that no impurities get into the bearing.

− Tighten all screw plugs in the tapped holes (22), (23), (24),(27) to the necessary torque rates:

Screw plug threads G 3/8 G 1/2 G 3/4 G1 G 1 1/4 G 1 1/2 G2 G 2 1/2

Torque [Nm] for plugs 30 40 60 110 160 230 320 500

with injection-moulded
plastic sealing ring

Torque [Nm] for plugs 34 60 85 130 240 300 330 410

with flexible sealing ring

− Check that
• the top sight glass (5) is tight, the screws should be hand-tight.
− Retighten the screws for oil inlet and outlet, and for the thrust parts (if existing). The necessary
torque rates depend on the screw connections used.

In case thermo sensor or/and oil sump thermometer are used:

− Check if they are tight (according the manufacturer's instructions).
− Fill up the oil supply system with lubricant. Use a lubricant with a viscosity as indicated for the
specific bearing operation.
− Start operating the oil supply system in order to fill the bearing with lubricant.

EF.C., − Remove the protective layer from the top sight glass (5).
EF.L., Continue as already mentioned above.
EF.Y.

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 Installation and Operation

8.2 Trial run

− Before the trial run, check the following:

• the way the oil supply system functions (see also the Technical Documentation of the
Installation).The lubricant quantity at the bearing oil inlet must correspond to the values
indicated in the EDP-calculations.
• that the temperature monitoring equipment works.
EFT.. • that the water cooling installation works.

Attention!
Not enough lubricant leads to
temperature rises and thus damage of the bearing.

Too much lubricant leads to

leakages.

The bearing is ready for operation.

− Supervise the bearing during the trial run (5-10 operating hours).
Pay special attention to:
• the way the oil supply installation works (necessary lubricant quantity, lubricant temperature,
lubricant pressure before entering the bearing)
• bearing temperature
• sliding noises of the shaft seals
• tightness
• occurrence of inadmissible vibrations.

Attention!
If the bearing temperature exceeds the calculated value by 15 K (see bearing calculation) stop the
installation immediately. Carry out an inspection of the bearing as described under Instructions for
Service and Inspection of the Slide Bearings Type EF with External Oil Supply.

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 EF with external oil supply

9 Glossary

Baffle With bearing types 10 and 20 the baffles are assembled externally in front of the shaft
seals. The baffle, made of reinforced polyamide, protects the bearing from dust and
water.

Rigid labyrinth seal The rigid labyrinth seal (type 20) is used with slide bearings type E with high oil
throughput. It corresponds to the protective system IP44 and is made of an aluminium
alloy.
The rigid labyrinth seal is built of two halves, flanged at the housing. The labyrinths that
wipe out the lubricant are arranged into two groups. The first two labyrinths , installed
inside keep back most of the lubricant. Five further labyrinths protect the bearing from
outside. They prevent the lubricant overflow and the ingress of impurities. The overflow
lubricant is collected into a chamber between the both groups of labyrinths. Through the
return bores the lubricant flows back into the bearing.

Spherical seating The spherical seating is a special feature enabling the alignment of the shell in the
housing. The shell is seated on two spherical seatings. The advantages of the spherical
seating are:
• easy at assembly
• good heat transfer from the shell to the housing
• suitable for such applications with high thrust or journal loads.

Dust flinger In the case of bearing types 10 and 20 a light alloy ring is clamped on the shaft in front
of the shaft. This ring fits into a groove in the seal carrier or the rigid labyrinth seal, thus
building a labyrinth. The labyrinth protects the shaft exit against low pressure that could
otherwise " absorb " the lubricant. Low pressure occurs for instance in the case of
rotating discs, such as couplings or cooling discs.

Floating labyrinth The floating labyrinth seal (type 10) in the seal carrier is used as a shaft seal in the case
seal of bearings type E operating under normal conditions. It prevents the lubricant and
lubricant mist coming out and the ingress of impurities. The floating seal has a high
capacity of resistance to wear. It is made of a high-performance, high temperature
stability and electrically insulated plastic material. The floating seal consists of two
halves held together by a garter spring. Both ends of the spring are hooked together. In
the case of slide bearings type EM the floating seal is mounted into a two-piece seal
carrier. The groove allows for radial movement of up to 1 mm. The seal is thus
insensitive to shaft radial displacement or deflection. The sealing effect is produced by
the baffles wiping off the lubricant from the shaft. The lubricant flows back into the
bearing via oil return opening.

Machine seal In the case of the flange mounted bearings, the machine seal reduces the influence of
positive and negative pressure in the machine thus preventing leakages at the inner
seal area. The space between the machine seal and the bearing housing must always
be vented to atmospheric pressure. The size of the gap between shaft and machine
seal influences the sealing effect.

RENK AG Werk Hannover RH-EFZEI-E Version: 1 Juli, 2002 A 53

Instructions
for Maintenance and Inspection

Slide Bearings Type EF

with self lubrication

RH
EFEWI
E – 7.02
Maintenance and Inspection

RENK AKTIENGESELLSCHAFT
Werk Hannover
Weltausstellungsallee 21
D
30539 Hannover
Telephone: (0511) 8601
0
Telefax: (0511) 8601
266
e
mail: [email protected]
http:\\www.renk.de

All rights reserved. Copy or reproduction without prior permission of RENK Aktiengesellschaft Hannover
prohibited.

2 RH
EFEWI
E Version: 1 Juli, 2002 Ó RENK AG Werk Hannover

 EF with self lubrication

Contents

Bearing Coding ..............................................................................................................................................5

General Drawing of the Slide Bearing EF with self lubrication ......................................................................7
General Drawing of the Loose Oil Ring..........................................................................................................9
General Drawing of the Floating Labyrinth Ring with Seal Carrier ..............................................................11
General Drawing of the Rigid Labyrinth Seal ...............................................................................................13
General Drawing of the Baffle ......................................................................................................................15
General Drawing of the Dust Flinger ............................................................................................................17
1 Considerations for Use ...........................................................................................................................19
2 Safety Instructions ..................................................................................................................................20
3 Operating Instructions after Standstill ..................................................................................................21
4 Maintenance Schedule ...........................................................................................................................22
5 Oil Change................................................................................................................................................23
6 Dismantling of the Bearing .....................................................................................................................24
6.1 Tools and equipment .......................................................................................................................24
6.2 Use of lifting equipment ...................................................................................................................24
6.3 Preparation for dismantling..............................................................................................................26
6.4 Dismantling of the shaft seal
outboard side ..................................................................................27
6.4.1 Floating labyrinth seal (Type 10) ...............................................................................................27
6.4.2 Floating labyrinth seal with dust flinger (Type 11).....................................................................27
6.4.3 Floating labyrinth seal with baffle (Type 12)..............................................................................27
6.4.4 Rigid labyrinth seal (Type 20) ....................................................................................................27
6.4.5 Rigid labyrinth seal with dust flinger (Type 21) .........................................................................27
6.4.6 Rigid labyrinth seal with baffle (Type 22) ..................................................................................27
6.5 Dismantling of the top half of the housing .......................................................................................28
6.6 Removal of the top half of the shell .................................................................................................28
6.6.1 Dismantling of the loose oil ring................................................................................................28
6.6.2 Dismantling the machine side shaft seal ..................................................................................29
6.7 Removal of the bottom half of the shell ...........................................................................................29
6.8 Dismantling of the machine seal ......................................................................................................29
7 Cleaning and Checking of the Bearing..................................................................................................30

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Maintenance and Inspection

8 Assembly of the Bearing.........................................................................................................................32

8.1 Fitting in the bottom half of the shell................................................................................................32
8.2 Assembly of the shaft seal
machine
side ......................................................................................33
8.3 Installation of the loose oil ring ........................................................................................................35
8.4 Fitting in the top half of the shell......................................................................................................36
8.5 Closing of the bearing ......................................................................................................................37
8.6 Assembly of the Seals
Outboard Side...........................................................................................39
8.6.1 Floating labyrinth seal (Type 10) ...............................................................................................39
8.6.2 Floating labyrinth seal with dust flinger (Type 11).....................................................................43
8.6.3 Floating labyrinth seal with baffle (Type 12)..............................................................................44
8.6.4 Rigid labyrinth seal (Type 20) ....................................................................................................44
8.6.5 Rigid labyrinth seal with dust flinger (Type 21) .........................................................................46
8.6.6 Rigid labyrinth seal with baffle (Type 22) ..................................................................................46
9 Starting Operation after Inspection.......................................................................................................47
10 Corrosion Protection for Longer Standstill Periods ............................................................................48
11 Transport Protection...............................................................................................................................48
12 Glossary ...................................................................................................................................................49

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 EF with self lubrication

Bearing Coding

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Maintenance and Inspection

Œ  Ž   ‘

Type Housing Heat Dissipation Shape of Bore and Type of Thrust part Size
Diameter
Lubrication

E F
flange mounted N
natural cooling L
plain cylindrical bore with Q
without thrust part 9 80£D£100
bearing loose oil ring (non
locating bearing )
W
water cooling 11 100£D£125
(finned cooler in oil sump ) B
plain sliding surfaces with oil
grooves (locating bearing) 14 125£D£160

E
taper land faces for one 18 160£D£200

sense of rotation
(locating bearing) 22 200£D£250

K
taper land faces for both 28 250£D£315

senses of rotation
(locating bearing)

Example for bearing coding:

Œ  Ž   ‘
E F N L Q 22
200 Type E slide bearing with flange mounted housing, natural cooling
plain cylindrical bore with loose oil ring, non locating bearing without thrust part,
size 22, diameter 200.

Shaft seals Type 10
floating labyrinth seal (IP 44)

Type 11
floating labyrinth seal with dust flinger (IP 54)
Type 12
floating labyrinth seal with baffle (IP 55)

Type 20
rigid labyrinth seal (IP 44)

Type 21
rigid labyrinth seal with dust flinger (IP 54)
Type 22
rigid labyrinth seal with baffle (IP 55)

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 self lubrication

General Drawing of the

Slide Bearing EF

with self lubrication

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E Version: 1 Juli, 2002 7

 5 6 7 8 9

4
10

11

3 12

13
2
14

15
1
16

17
xxx

x
18
xxx

19

20

21

22

23

24

27 26 25
 1 Top half of the housing
2 Hole for positioning pin
3 Pin for positioning shell
4 Oil filling hole
5 Top sight glass
6 Eye bolt
7 Screw (not included in delivery)
8 Screw
9 Tapped hole ( in the top and bottom halves of the shell, up size 14 )
10 Machine seal
11 Top half of the shell
12 Screw (split line of the housing)
13 Bottom half of the shell
14 Spherical seating
15 Engraved number
shell
16 Spigot
17 Tapped hole
18 Screw (not included in delivery)
19 Screw (split line of the shell)
20 Engraved numbers
housing
21 Bottom half of the housing
22 Tapped hole for journal bearing temperature measurement
23 Oil sight glass
24 Tapped hole for oil sump temperature measurement
25 Outlet/Inlet cooling water (Type E.T..)
26 Cooler ( Type E.T..)
27 Hexagon head plug (Oil drain plug)
 self lubrication

General Drawing of the

Loose Oil Ring

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33

34

35

36
33 Loose oil ring
34 Dowel pin
35 Hole
36 Screw
 self lubrication

General Drawing of the

Floating Labyrinth Seal

with Seal Carrier

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 Bearing side
37

38
43

42

39

41

40

Outer view
47 44

46

45
37 Seal carrier
top half
38 Garter spring
39 Groove
40 Seal carrier
bottom half
41 Bottom half of the seal
42 Top half of the seal
43 Anti
rotation pin
44 Screw
45 Engraved number
46 Groove ( Type 11 )
47 Engraved number
 self lubrication

General Drawing of the

Rigid Labyrinth Seal

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 48
49

54

50 (2x)

51

53

52
48 Rigid labyrinth seal
top half
49 Screw
50 Screw (split line)
51 Groove ( Type 21 )
52 Rigid labyrinth seal
bottom half
53 Engraved number
54 Engraved number
 self lubrication

General Drawing

Baffle

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 55

56

57
55 Baffle
top half
56 Screw
57 Baffle
bottom half
 self lubrication

General Drawing of the

Dust Flinger

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LREE/WI
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 58

59 (2x)
58 Dust flinger
59 Screw (split line)
 EF with self lubrication

1 Considerations for Use

The instructions for maintenance and inspection are addressed to qualified technical personnel
(fitters, mechanic installers, mechanical engineers).

Read these instructions carefully before starting assembly.

Slide bearings of type EF are almost universally used in the engineering industry. Therefore it is not
possible to provide detailed information on all possible types and range of applications for these
bearing types. For instance, the position of the connection points for supply and monitoring
equipment is determined by the place of application ( in the following called " installation " ).
Please keep ready the guidelines with the technical documentation before starting assembly and
operation of the slide bearings.

Additional technical documentation with detailed information is supplied in the case of special
design bearings. Please contact RENK Export or Domestic Department for supplementary
information on bearings. Please indicate the bearing coding and the full reference number, too.

Following indications should be observed when reading these instructions.

Safety instructions are marked as follows:

Caution !
Warning of dangers for personnel.
Example: Warning of injury

Attention!
Warning of damage for the bearing or installation.

Useful recommendations and additional information are framed.

EFW.. This is how chapters, instructions or recommendations are marked when referring to a single type
or size of a bearing.
Example: Slide bearing type EF with water cooler

Instruction follows.

· Beginning of an enumeration.

( ) This is how the different parts of a bearing as described in the general drawings ( numbers )
are marked in the text.

- Use the enclosed check
list before starting assembly or operation. Copies available on request.
- The check list provides the experienced mechanical fitters of RENK bearings with the
necessary instructions for installation and operation.

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Maintenance and Inspection

2 Safety Instructions

Danger!
The maintenance and inspection of the slide bearings should be carried out by:
· persons nominated by the safety representative
· persons correspondingly trained and instructed
· persons with knowledge on appropriate standards, regulations and accident
. prevention rules
· persons with knowledge on first
aid measures and local rescue centers.

Warning of injury!
Before starting work on the bearing:

Switch off the installation.

Make sure the installation is not in operation.
Never lift or transport machines, etc.by the bearing eye bolts. These are only intended
for assembly and dismantling of the bearing !

Warning of injury!
Do not grab such heavy bearing parts as the housing during assembly or dismantling
work. This could result in bruising or injury to hands !

Attention!
All metal parts of a slide bearing consisting of top and bottom half such as the housing, shells,
shaft seals are marked by engraved numbers. Fit together only the parts with the same number.

Attention!
In case · the admissible bearing temperature exceeds 15 K
· inadmissible vibrations occur
· unusual noises or odours are noticed
· monitoring equipment triggers alarm
shut down the installation and inform the maintenance personnel in charge.

Attention!
Do not operate the bearing below the transition speed values indicated in the bearing calculation,
thus avoiding inadmissible operating conditions, which could lead to damage to the bearing.

Attention!
Please observe our leaflet Technical Information No. 85 which refers to various sealing compounds
for extended technical applications.

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 EF with self lubrication

3 Operating Instructions after Standstill

- Clean the external parts of the bearing. Dust and dirt impede the radiation of the heat.
- Check with the instructions for the use of the lubricating oil if an oil change is necessary.
Depending on the duration of the standstill an oil change is either prescribed or recommended.
Carry out the oil change as indicated in Chapter 5.
- Check the oil level
- If necessary, refill with lubricant by using the oil filling hole (4).
The refilling oil should be of the same type as already used.
The oil level limits are as follows:
minimum oil level: bottom of the oil sight glass
maximum oil level: top of the oil sight glass

- Retighten the and screws (12), (8), (18) to the following torque rates:

Bearing Size 9 11 14 18 22 28

Torque [Nm] for 69 69 170 330 570 1150

µtot = 0,1 (lightly oiled)

- Check the firm position of the top sight glass (5).

- Check the firm position of the oil sight glass (23).
In case a thermo sensor or/and an oil sump thermometer are used:
- Check if they are well fitted (see also the manufacturer's instructions).
- Retighten all screw plugs in the tapped holes (4), (22), (24) (27) to the necessary torque rates:

Screw plug threads G 3/8 G 1/2 G 3/4 G1 G 1 1/4 G 1 1/2 G2 G 2 1/2

Torque [Nm] for plugs 30 40 60 110 160 230 320 500

with moulded on plastic
seal

Torque [Nm] for plugs 34 60 85 130 240 300 330 410

with elastic seal

- Check the functioning of the temperature monitoring equipment.

EFW.. - Check the functioning of the cooler.

The bearing is now ready to work.

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Maintenance and Inspection

4 Maintenance Schedule

Maintenance work Deadline

Exterior cleaning of the bearing every 100
1000 hours

Oil change Bearing in reversing operation every 5000 operating hours.

Bearing in continous operation every 8.000 operating hours
(please observe also the indications for the use of the
lubricating oil).

Bearing inspection During prevention maintenance work for the installation.

Immediately if:

· the bearing temperature exceeds 15 K over the indicated

value (see the EDP
calculations)

· unusual operating noises occur

· unusual changes of the lubricating oil become visible

· increased oil level in the case of bearing type EFW....

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5 Oil Change

Risk of pollution!
Please observe the instructions for the use of the lubricating oil. The manufacturer can provide
information on waste oil disposal.

- Shut down the installation and secure it against unintended operation.

- Take all necesarry measures to collect the whole quantity of the lubricating oil.
- Drain off the lubricating oil in still warm condition. Impurities and residues will thus be
scavenged.
- Unscrew the hexagon head plug (27). Drain off the lubricating oil and collect it.

Attention!
In case the lubricating oil contains unusual residues or is visibly changed, eliminate the causes. If
necessary, carry out an inspection.

- Tighten the hexagon head plug (27) to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 30 30 30 40 60 60

- Remove the screw plug from the oil filling hole (4).

Attention!
Make sure that no impurities get into the bearing.

- Use a lubricant with the viscosity indicated on the bearing type plate. Fill the lubricant through
the oil filling hole (4) up to the middle point of the oil sight glass (23).
The oil level limits are as follows:
minimum oil level: bottom of the oil sight glass
maximum oil level: top of the oil sight glass

Attention!
· Not enough lubricant leads to temperature rises and thus to damage to the bearing.
· Too much lubricant leads to leakages. In the case of bearings with lubrication by loose oil
ring too much lubricant could have a considerable breaking effect on the oil rings,
thus leading to damage to the bearing.

- Tighten the screw plug into the oil filling hole (4) to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 30 30 30 40 60 60

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Maintenance and Inspection

6 Dismantling of the Bearing

6.1 Tools and equipment

- Following tools and equipment are necessary:

· Allan key set
· Wrenching key set
· Open
jawed spanner set
· Feeler gauges (up 0,05mm)
· Caliper gauge
· Emery paper, plain scraper
· Oil stone
· Lifting equipment
· Permanent sealing compound
· Clean (close weave) rags
· Oil with the viscosity indicated (see bearing type plate)
· Detergents
· Liquid screw locking compound (e.g.LOCTITE 242)
· Liquid sealing compound and Teflon tape.

6.2 Use of lifting equipment

Risk of injury!

Before transport or lifting check if the eye bolts are tight! Insecure eye bolts could
result in bearing becoming loose.
Before moving the bearing by the eye bolts make sure that the screws at the split line
are tightened, otherwise the bottom half of the bearing could become detached.
Make sure that the eye bolts are not exposed to bending stress, otherwise the bolts
could break.

Follow exactly the instructions for the use of the lifting equipment.

- Use lifting equipment for following assembly and transport works:

Transport/Assembly of: Use lifting equipment for the following bearing sizes

Whole bearing unit 9
28

Top half of the housing 14
28

Bottom half of the housing 11
28

Shells 14
28

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 EF with self lubrication

Following steps are to be observed before using the lifting equipment:

Whole bearing unit

- Check if the screws are tight (12):

Bearing size 9 11 14 18 22 28

Torque [Nm] for 69 69 170 330 570 1150

µtot = 0,1 (lightly oiled)

- Check if the eye bolts are tight (6).

- Connect the lifting equipment to the eye bolts (6).

Top half of the housing

- Check if the eye bolts are tight (6).
- Connect the lifting equipment to the eye bolts (6).

Bottom half of the housing

- Screw two eye bolts (6) with suitable threads tight into the cross
placed opposite tapped holes
(17).

Bearing size 9 11 14 18 22 28

Tapped hole M 12 M 12 M 16 M 20 M 24 M 30

- Connect the lifting equipment to the eye bolts (6).

Shells
- Screw two eye bolts or screw hooks with suitable threads tight into the tapped holes (9):

Bearing size 14 18 22 28

Tapped hole M8 M 12 M 12 M 16

- Connect the lifting equipment to the screw hooks.

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 Maintenance and Inspection

6.3 Preparation for dismantling

Attention!
Make sure that the work place is clean. Contamination and damages to the bearing, especially of
the working surfaces, have a negative influence on the operating quality and could lead to
premature damage.

Attention!
Do not use any violence or force!

- Shut down the installation and ensure it against unintended operation.

EFW..
- Interrupt the cooling water supply.
- Dismantle all thermo sensors from the connection holes.
- Take all necessary measures to collect the lubricating oil.
- Unscrew the hexagon head plug (27) and collect the lubricating oil.

Risk of pollution!
Please observe the instructions for the use of the lubricating oil. The manufacturer can provide
necessary information on waste oil disposal.

- Tighten the hexagon head plug (27) to the following torque rates

Bearing size 9 11 14 18 22 28

Torque (Nm] 30 30 30 40 60 60

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 EF with self lubrication

6.4 Dismantling of the shaft seal
outboard side

- Dismantle the outboard side seals of the bearing.

Proceed correspondingly to the seal type:
· Floating labyrinth seal (Type 10) Chapter 6.4.1
· Floating labyrinth seal with dust flinger (Type 11) Chapter 6.4.2
· Floating labyrinth seal with baffle (Type 12) Chapter 6.4.3
· Rigid labyrinth seal (Type 20) Chapter 6.4.4
· Rigid labyrinth seal with dust flinger (Type 21) Chapter 6.4.5
· Rigid labyrinth seal with baffle (Type 22) Chapter 6.4.6
Type 6.4.1 Floating labyrinth seal (Type 10)
10
- Loosen all screws (44) and turn them off.
- Remove simultaneously in axial direction both top half (37) and bottom half (40) of the seal
carrier from the housing.
- Shift a little (about 20 mm) the top half (42) of the seal. Tilt it over carefully until the garter spring
(38) unbends.

Warning of injury!
During dismantling of the floating labyrinth seal hold tight the garter spring (38) which
is under tension and could bounce back and lead to injury.

- Open the garter spring (38) and remove the bottom half of the seal (41) from the shaft.

Type 6.4.2 Floating labyrinth seal with dust flinger (Type 11)
11
- Dismantle the dust flinger (58). Loosen the screws (59) and take out the dust flinger (58) from
the groove (46) of the seal carrier. Remove both halves of the dust flinger.
- Go on as indicated for type 10 (see Chapter .4.1).
Type
6.4.3 Floating labyrinth seal with baffle (Type 12)
12
- Unscrew both top (55) and bottom (57) halves of the baffle by untightening the screws (56).
- Go on as indicated for type 10 (see Chapter 6.4.1).

Type 6.4.4 Rigid labyrinth seal (Type 20)

20
- Loosen all screws (49) and take them out.
- Take out the screws (50).
- Remove simultaneously in axial direction both top (48) and bottom (52) halves of the rigid
labyrinth seal.

Type 6.4.5 Rigid labyrinth seal with dust flinger (Type 21)
21
- Dismantle the dust flinger (58). Loosen the screw (59) and take out the dust flinger (58) from the
groove (51) of the rigid seal. Remove both halves of the dust flinger.
- Go on as indicated for type 20 (see Chapter 6.4.4).
Type 6.4.6 Rigid labyrinth seal with baffle (Type 22)
22
- Unscrew the top half (55) and the bottom half (57) of the baffle by untightening the screws (56).
- Go on as indicated for type 20 (see Chapter 6.4.4).

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Maintenance and Inspection

6.5 Dismantling of the top half of the housing

- Remove the screws (8).

- Remove the screws (12).
- Lift the top part of the housing (1) until the top part of the housing can be moved in axial line
over the shell, without touching it.

6.6 Removal of the top half of the shell

- Unscrew the screws (19) and lift the top half of the shell (11).

Attention!
Do not damage the thrust and radial working surfaces.

Attention!
In the case of insulated housings (white plastic insulating foil) avoid any jamming of the top half of
the shell when you lift it up
Jamming could lead to damage of the insulating foil in the bottom half of the housing.

6.6.1 Dismantling of the loose oil ring

- Open both split lines of the loose oil ring (33) by untightening and taking out the screws (36).
Separate both halves of the loose oil ring (33) carefully without using any tools or other devices.

I II

33

33 33

36

Illustration 1: Opening of the loose oil ring

To check the geometry of the loose oil ring put it together as follows:
- Press the positioning pin (34) into the hole (35).
- Adjust both halves of the loose oil ring till the split lines match each other.
- Tighten the screws (36).

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 EF with self lubrication

6.6.2 Dismantling the machine side shaft seal

- Shift a little (about 20 mm) the top half (42) of the seal. Tilt it over carefully until the garter spring
(38) unbends.

Warning of injury!
During dismantling of the floating labyrinth seal hold tight the garter spring (38) which
is under tension and could bounce back and lead to injury.

- Open the garter spring (38) and turn the bottom half of the seal (41) in opposite direction from
the anti
rotation pin out of the integrated seal groove of the bottom half of the housing.

6.7 Removal of the bottom half of the shell

Attention!
Make sure that all bearings mounted on a shaft line are opened. Loosen the screws at the split line
of the housings.

Attention!
The lifting equipment should not come into contact with the seal and working surfaces of the shaft.

- Lift the shaft up to the point where shaft and bottom half of the shell (13) do not touch each
other any more. Protect the shaft against unintended movement.
- Turn the bottom half of the shell (13) out of the bottom half of the housing (21) and remove it
from the shaft.

Attention!
If the bottom half of the shell (13) is provided with metal tabs (28) do not remove them. They
regulate the oil level in the oil pockets.

6.8 Dismantling of the machine seal

Usually it is not necessary to dismantle the machine seal (10) if maintenance works are carried out.
If due to certain reasons the split machine seal must be dismantled please observe that this
operation can be carried out only from the inner part of the machine. Loosen the screws at the
split line of the machine seal and remove the screws (7).
Non
split machine seals can be dismantled only after dismantling the machine shield or the shaft
completely.
In the case the machine seal is equipped with a hamp packing, some visible changes can be
noticed, such as : tallow excess, black colour of the seal due to temperature development. Even in
such cases it is not necessary to renew the hamp packing. Colour changes will appear with a new
hamp packing too, until the seal clearance adjusts during operation.

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 Maintenance and Inspection

7 Cleaning and Checking of the Bearing

Attention!
Use only non
aggressive detergents such as for instance
· VALVOLINE 150
· Alcaline cleaning compounds (pH-value 6 to 9, short reaction time).

Warning of injury!
Please observe the instructions for the use of the detergents.

Attention!
Never use cleaning wool or cloth. Residues of such materials left in the bearing could lead to
excessive temperatures.

- Clean the following parts thoroughly:

· top half of the housing (1)
· bottom half of the housing (21)
· top half of the shell (11)
· bottom half of the shell (13)
· sealing surfaces of the top half (37) and bottom half (40) of the seal carrier or of the rigid
labyrinth seal
· loose oil ring (33).
EFW.. - Check the condition of the cooler (26).
In cases where the cooler (26) is incrusted with oil sludge:
- Dismantle the cooler. Remove the incrustation by using for instance a wire brush.
- Install the cooler (26) into the bearing.

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 EF with self lubrication

- Carry out a visual check of the wear condition of all bearing parts. The following graph provides
information on the parts that must be replaced in case of wear.The right evaluation of the wear
condition, especially of the working surfaces of the shell, implies a lot of experience. If in doubt,
replace the worn part with new ones.

Bearing part Wear condition Maintenance procedures

Shell Scoring Bearing temperature before inspection:

· not increased
no new shells
· increased
new shells

White metal lining damaged New shell

Bow wave ridges New shells

Shaft seal Baffles broken or damaged New shaft seal

Loose oil ring Geometrical form ( roundness, New loose oil ring
flatness ) visibly changed

Size - Check the projection of the positioning pin (3) according to the values indicated below:
9
14
Bearing size 9 11 14 18 22 28

Projection of the 7 8 10 12 14 16
positioning pin (4) mm

In case the projection is less than indicated,

- drive the positioning pin (3) into the top half of the housing (1) until the indicated value is
reached.

insulated - Check the insulating layer of the spherical seating (14) of the top half (1) and bottom half (21) of
bearings
the housing. In case of damage contact the RENK
sales agency in charge.

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 Maintenance and Inspection

8 Assembly of the Bearing

Attention!
Remove all impurities or other objects such as screws, nuts, etc. from inside the bearing. If left
inside they could lead to damage of the bearing. Cover up the opened bearing during work breaks.

Attention!
Carry out all assembly operations without making use of force.

Attention!
Secure all screws of the housing, flange and at the split line with a liquid screw locking compound
(e.g.LOCTITE 242).

8.1 Fitting in the bottom half of the shell

EF..E Attention!
Mounting the bottom half of the shell (not marked with an arrow) correctly will ease the assembly
of the top half shell (marked with an arrow) (see chapter 8.4).

- Apply some lubricant to the spherical seating (14) in the bottom half of the housing (21) and to
the working surfaces of the shaft. Use the same type of lubricant as indicated for bearing
operation
( see type plate ).
- Place the bottom half of the shell (13) on the working surface of the shaft. Turn the bottom half
of the shell (13) into the bottom half of the housing (21) with the split line surfaces of both halves
in true alignment.

In case the bottom half of the shell doesn’t turn in easily, check the position of the shaft and the
alignment of the housing

EF..B, Attention!
EF..K, These operations should be carried out most carefully. The thrust parts of the bottom shell must
EF..E not be damaged.

- Lower down the shaft till it sits on the bottom half of the shell (13).

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 EF with self lubrication

8.2 Assembly of the shaft seal
machine
side

The machine
side shaft seal is, as standard, a floating labyrinth seal. The integrated seal groove is
in the top and bottom halves of the housing.

Warning of injury!
During assembly hold the garter spring ends (38) securely to avoid them suddenly
releasing and causing possible injury!

Check the movement of the floating labyrinth seal on the shaft in the seal area outside the housing:
- Put the garter spring (38) around the shaft and hook both ends into each other.
- Put both halves of the seal (41), (42) in their place on the shaft.
- Put the garter spring (38) into the groove (39).
- Turn the floating labyrinth seal on the shaft.

Attention!
The floating labyrinth seal should turn easily on the shaft. A jammed seal could lead to overheating
during operation and even to shaft wear.
If the floating labyrinth seal jams,

dismantle the seal and

remove the worn parts of the seal carefully, by using emery paper or a plain scraper.

- Dismantle the floating labyrinth seal.

- Apply sealing compound to the guide surfaces of the integrated seal groove in the bottom half
of the housing.

Illustration 2: Applikation of sealing compound to the integrated seal groove

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Maintenance and Inspection

- Apply a uniform layer of sealing compound to the seal surfaces and to the split line surfaces of
both halves of the seal (41), (42).

Illustration 3: Application of sealing compound to the floating labyrinth seal

Please observe the instructions for the use of sealing compound.

- Place the bottom half of the seal (41) with the labyrinths onto the shaft.
- The oil return holes at the bearing side must be clear and open.
- Turn the seal in opposite direction from the anti
rotation pin into the groove of the housing until
the split lines of the bottom half of the housing and the bottom half of the seal match each
other.
- Remove the rests of sealing compound.
- Push the garter spring into the integrated seal groove between the bottom half of the housing
and the seal until both ends jut out from the split line.
- Place the top half of the seal with the cam facing the inside of the bearing on the bottom half of
the seal.
- Stretch the garter spring till both ends can be hooked.

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 EF with self lubrication

8.3 Installation of the loose oil ring

- Open both split lines of the loose oil ring (33) by untightening and removing the screws (36).
Separate both halves of the loose oil ring (33) carefully without using any tools or other devices.

I II

33

33 33

36

Illustration:4 Opening of the loose oil ring

- Place both halves of the loose oil ring into the shell groove (13) around the shaft. Press the
positioning pin (34) of each split line into the corresponding hole (35).
- Adjust both halves of the loose oil ring till the split lines match each other.

21
34

33

33 13

llustration 5: Installation of the loose oil ring

- Tighten the screws (36) to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 1,4 1,4 1,4 2,7 2,7 2,7

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 Maintenance and Inspection

8.4 Fitting in the top half of the shell

- Apply some lubricant to the working surfaces of the shaft. Use the same type of lubricant as
indicated for bearing operation (see type plate).
- Check if the engraved numbers (15) on the bottom and top halves of the shell correspond.
- Place the top half of the shell (11) on the shaft; both engraved numbers (15) should be on the
same side.

Attention!
An incorrectly placed shell could jam the shaft thus leading to the damage of both shaft and
bearing.

EF..B, Attention!
EF..K, Place the top half of the shell carefully on the shaft. The thrust parts of the top half of the shell
EF..E should not be damaged.

insulated In the case of bearings arranged for insulation monitoring, connect the black cable for insulation
bearings monitoring to the shell.
According to the bearing type, there are two possibilities of connection.
1. The black cable is provided with a cable connector.
- Plug the cable with the cable connector into the counterpart available on the top of the shell.
- Lead the cable through the cable gland in the bottom half of the housing and out of the
bearing.
- Tighten the cable gland oil
tight.
2. The black cable is provided with an eyelet.
- Fasten the cable with the eyelet to the split line of the shell, by using one of the shell joint bolts.
- Lead the cable through the cable gland in the bottom half of the housing and out of the
bearing.
- Tighten the cable gland oil
tight.

- Tighten up the screws (19) to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 8 8 20 69 69 170

- Check the split line of the shell by using a feeler gauge. The split line gap should be less than
0,05 mm. If the split line is greater than this, dismantle both top and bottom (11),(13) halves of
the shell. Rework the split line surfaces of the top half (11) and bottom half (13) of the shell with
an oil stone.
- Check the mobility of the loose oil ring (33).

EF.L. A guide bush in the top half of the shell secures the function of the loose oil ring.
Marine
Bearing - Check the mobility of the loose oil ring (33) in the guide bush.

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 EF with self lubrication

Shells with taper land faces suitable only for one direction of rotation are marked with an arrow on
EF..E
the top half shell, which indicates the sense of rotation of the shaft.
The arrow indicates the allowed direction of shaft rotation after completion of the bearing
assembly.
- Before mounting the top half of the housing check that the proposed direction of rotation of the
shaft corresponds to the direction indicated by the arrow on the top half of the shell.
- If the directions match, continue the assembly of the bearing.
- If the directions do not match, the shell must be disassembled, re
aligned and mounted again.

Attention!
A wrongly placed shell, without observance of the direction of rotation of the shaft, impairs the
operational safety of the bearing.

8.5 Closing of the bearing

- Check the true alignment of the shell (11), (13) and bottom half (21) of the housing.

The positioning pin (3) in the top half of the housing fits in the corresponding hole (2). The shell is
thus placed into its right position.

- Check if the engraved numbers (20) on the top and bottom halves of the housing correspond.
- Clean the split line surfaces of the top and bottom halves (1), (21) of the housing.
- Apply sealing compound over the whole surface of the split line of the bottom half (21) of the
housing.

Please observe the instructions for the use of sealing compound.

- Place the top half of the housing carefully into the machine shield, without touching the seals or
the shell.
- Lower the top half of the housing (1) vertically on the bottom half of the housing (21). Lower the
top half of the housing (1) till the split line of the housing is not visible any more.
- Gently hit the bottom half of the housing (21) with a nylon hammer, thus ensuring the alignment
of the spherical seating.
- Insert the screws (12). Tighten them hand
tight.
- Insert the screws (8). Tighten them to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 69 69 170 330 570 1150

µtot = 0,1 (lightly oiled)

- Tighten the screws (12) of the housing crosswise to the same torque rates.

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 Maintenance and Inspection

insulated Insulation monitoring

bearings
In the case of electric insulated bearings provided with insulation monitoring, the cable coming out
of the housing must be connected in a professional manner.
According to the type supplied, please follow the assembly instructions given below.
a) The cable is very short and provided with a further cable connector at the end of it.
This cable is ready for connection to the housing.
The bottom half of the housing is provided with the counterpart.
- Plug the cable connector into the counterpart.

Attention!
This connection bypasses the electrical insulation of the bearing.
In the case of electric machines, make sure at least one bearing is electrically insulated.

To check the electrical insulation, interrupt the connection cable
housing. Check the electrical
resistance with a suitable measuring instrument. Make sure that both bearings and the coupling
are electrically insulated.
b) The cable has a free end. In this case the customer has to make the connection.

Attention!
If only one bearing is insulated, the end of the cable must not be earthed.

Any further connection depends on the customer’s requirements related to the insulation
monitoring and can not therefore be described here.

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 EF with self lubrication

8.6 Assembly of the Seals
Outboard Side

- Assemble the outboard side seals.

Proceed according to the seal type used:
· Floating labyrinth seal (Type 10) Chapter 8.6.1
· Floating labyrinth seal with dust flinger (Type 11) Chapter 8.6.2
· Floating labyrinth seal with baffle (Type 12) Chapter 8.6.3
· Rigid labyrinth seal (Type 20) Chapter 8.6.4
· Rigid labyrinth seal with dust flinger (Type 21) Chapter 8.6.5
· Rigid labyrinth seal with baffle (Type 22) Chapter 8.6.6

Type 8.6.1 Floating labyrinth seal (Type 10)

10

Warning of injury!
During assembly hold the garter spring ends (38) securely to avoid them suddenly
releasing and causing possible injury!

Check the movement of the floating labyrinth seal on the shaft in the seal area outside the housing.
- Put the garter spring (38) around the shaft and hook both ends into each other.
- Put both halves of the seal (41), (42) in their place on the shaft.
- Put the garter spring (38) into the groove (39).
- Turn the floating labyrinth seal on the shaft.

Attention!
The floating labyrinth seal should turn easily on the shaft. A jammed seal could lead to overheating
during operation and even to shaft wear.
If the floating labyrinth seal jams,

dismantle the seal and

remove the worn parts of the seal carefully, by using emery paper or a plain scraper.

- Dismantle the floating labyrinth seal.

Ó RENK AG Werk Hannover RH
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Maintenance and Inspection

- Apply a uniform layer of sealing compound to the guide surfaces and to the split line surfaces
of both halves of the seal (41), (42).

Please observe the instructions for the use of sealing compound.

Illustration 6: Application of sealing compound to the floating labyrinth seal

- Press the bottom half of the seal (41) against the shaft.
- Place the top half of the seal (42) on the shaft and align both halves of the seal to each other.
- Place the garter spring (38) into the groove (39) and stretch until both ends can be hooked.

43 42 1

38 41 21

Illustration 7: Assembly of the floating labyrinth seal

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 EF with self lubrication

- Place in true alignment the split line of the floating labyrinth seal and the split line of the seal
carrier.
- Check that both engraved numbers (45) and (47) on top and bottom halves of the seal carrier
(37), (40) correspond.
- Clean the following parts:
· the seal surfaces of the top (37) and bottom (40) half of the seal carrier (the groove of the
floating labyrinth seal, the flange surfaces)
· the split line surfaces of the top (37) and bottom (40) half of the seal carrier
· the flange surfaces of the housing.
- Apply a uniform layer of sealing compound to:
· the lateral surfaces of the groove at the top (37) and bottom (40) half of the seal carrier
· the flange surfaces of the top (37) and bottom (40) half of the seal carrier
· the split line surfaces of the bottom half of the seal carrier (40).

Please observe the instructions for the use of sealing compound.

Illustration 8: Application of sealing compound to the seal carrier

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Maintenance and Inspection

- Place the top half of the seal carrier (37) on the top half of the seal (42). Press the bottom half
(40) of the seal carrier against it. Push the shaft seal completely into the housing.

37

43

42

Illustration 9: Assembly of the seal carrier

- Place in true alignment the split lines of the seal carrier and the housing.
- Tighten up the screws (44) to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 8 8 8 20 20 20

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 EF with self lubrication

Type 8.6.2 Floating labyrinth seal with dust flinger (Type 11)
11
- Assemble the floating labyrinth seal with dust flinger as described in Chapter 8.6.1, Floating
labyrinth seal type 10.
- Place both halves of the dust flinger (58) in front of the shaft seal around the shaft. Loosely
screw in the screws (59).

58 37

e 46

Illustration 10: Clearance between dust flinger and seal carrier

EF..Q - Push the dust flinger (58) into the groove (46) of the seal carrier.
- Set the clearance "e" at the following figure around the whole unit:
maximum longitudinal extension of the shaft in operation + 1 mm
(Parameters indicated in the Technical Documentation of the Installation).
- Tighten up the screws (59) to the following torque rates:

Seal diameter [mm] 80
140 >140

Torque [Nm] 7 18

EF..B, - Push the dust flinger (58) into the groove (46) of the seal carrier.
EF..E, - Set the clearance "e" at 1 mm around the whole unit.
EF..K - Tighten the screws (59) to the following torque rates:

Seal diameter [mm] 80
140 >140

Torque [Nm] 7 18

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 Maintenance and Inspection

Type 8.6.3 Floating labyrinth seal with baffle (Type 12)

12
- Assemble the floating labyrinth seal with baffle as in Chapter 8.6.1, Type 10.
- Apply a uniform layer of sealing compound to the flange surfaces of the top half (55) and
bottom half (57) of the baffle.
- Screw · the top half of the baffle (55) onto the top half of the seal carrier (37)
· the bottom half of the baffle (57) onto the bottom half of the seal carrier (40).
- Tighten the screws (56) to the following torque rates:

Seal diameter [mm] 80
140 >140

Torque [Nm] 4 10

Type 8.6.4 Rigid labyrinth seal (Type 20)

20
- Check if the engraved numbers (53) and (54) on the bottom half (52) and top half (48) of the rigid
labyrinth seal correspond.
- Clean
· the flange surfaces of the top half (48) and bottom half (52) of the rigid labyrinth seal
· the split line surfaces of the top half (48) and bottom half (52) of the rigid labyrinth seal
· the flange surfaces of the housing.
- Apply a uniform layer of sealing compound to the following parts:
· the flange surfaces of the top half (48) and bottom half (52) of the rigid labyrinth seal
· the split lines of the bottom half (52) of the rigid labyrinth seal.

Please observe the instructions for the use of sealing compound.

Illustration 11: Application of sealing compound to the rigid labyrinth seal

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 EF with self lubrication

- Place the top half (48) of the rigid labyrinth seal on the shaft and press slightly the bottom half
(52) of the rigid labyrinth seal from below against it. Lightly push the rigid labyrinth seal
completely into the housing.
- Tighten the screws (50).
- Place in parallel alignment the split line of the rigid labyrinth seal and the split line of the
housing. Press the rigid labyrinth seal slightly from below against the shaft. Adjust the rigid
labyrinth seal in such a way that the clearance "f" between the shaft and the rigid labyrinth seal
at both split lines has the same figure.

1 48

f f

21 52

Illustration 12: Alignment of the rigid labyrinth seal

- Tighten the screws (49) to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 8 8 8 20 20 20

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 Maintenance and Inspection

Type 8.6.5 Rigid labyrinth seal with dust flinger (Type 21)
21
- Assemble the rigid labyrinth seal with dust flinger as indicated in Chapter 8.6.4, Type 20.
- Place both halves of the dust flinger (58) round the shaft, in front of the rigid labyrinth seal.
Mount the screws (59) loose.

58 48

e
51

Illustration 13: Clearance between dust flinger and rigid labyrinth seal
EF..Q - Push the dust flinger (58) into the groove (51) of the rigid labyrinth seal.
- Set the clearance "e" at the following figure around the whole unit:
maximum longitudinal extension of the shaft in operation + 1 mm
(Parameters are indicated in the Technical Documentation of the Installation).
- Tighten the screws (59) to the following torque rates:

Seal diameter [mm] 80
140 >140

Torque [Nm] 7 18

EF..B, - Push the dust flinger (58) into the groove (51) of the rigid labyrinth seal.
EF..E, - Set the clearance "e" at 1 mm around the whole unit.
EF..K - Tighten the screws (59) to the following torque rates:

Seal diameter [mm] 80
140 >140

Torque [Nm] 7 18

Type 8.6.6 Rigid labyrinth seal with baffle (Type 22)

22
- Assemble the rigid labyrinth seal with baffle as described in Chapter 8.6.4.
- Apply a uniform layer of sealing compound to the flange surfaces of the top half (55) and
bottom half (57) of the baffle.
- Tighten · the top half of the baffle (55) to the top half (48) of the rigid labyrinth seal
· the bottom half of the baffle (57) to the bottom half (52) of the rigid labyrinth seal.
- Tighten the screws (56) to the following torque rates:

Seal diameter [mm] 80
140 >140

Torque [Nm] 4 10

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 EF with self lubrication

9 Starting Operation after Inspection

- Fit the thermo sensors for:

· temperature measurement of the journal part in the tapped holes (22)
- Retighten all screw plugs in the tapped holes (22), (24), (27), (29) to the following torque rates:

Screw plug threads G 3/8 G 1/2 G 3/4 G1 G 1 1/4 G 1 1/2 G2 G 2 1/2

Torque [Nm] for plugs 30 40 60 110 160 230 320 500

with moulded on plastic
seal

Torque [Nm] for plugs 34 60 85 130 240 300 330 410

with elastic seal

- Check that the top sight glass (5) is tight.

- Check that the oil sight glass (23) is tight, the screws should be hand
tight.
- Carry out a visual check of the assembled bearing.
- Remove the screw plugs from the oil filling hole (4).

Attention!
Make sure that no impurities get into the bearing.

- Use a lubricant with the viscosity indicated on the bearing type plate. Fill the lubricant through
the oil filling hole (4) up to the middle point of the oil sight glass (22).
The oil level limits are as follows:
minimum oil level: bottom of the oil sight glass
maximum oil level: top of the oil sight glass

Attention!
· Not enough lubricant leads to temperature rises and thus to damages to the bearing.
· Too much lubricant leads to leakages. In the case of bearings with lubrication by loose oil
ring too much lubricant could have a considerable breaking effect on the oil rings,
thus leading to damages to the bearing.

- Tighten the screw plug into the oil filling hole (4) to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 30 30 30 40 60 60

- Check that the temperature monitoring equipment works.

EFW.. - Start operating the cooling water supply system and check its functioning.

The bearing is ready for operation.

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Maintenance and Inspection

- Supervise the bearing during the trial run ( 5
10 operating hours ).

Pay special attention to:
· oil level
· bearing temperature
· sliding noises of the shaft seals
· tightness
· occurrence of inadmissible vibrations.

Attention!
If the bearing temperature exceeds the calculated value by 15 K (see the EDP
bearing
calculations) stop the installation immediately. Carry out an inspection of the bearing and find out
the causes.

10 Corrosion Protection for Longer Standstill Periods

If you want to protect the bearing mounted on an installation against corrosion proceed as follows:
- Dismantle the bearing (see Chapter 6).
- Clean the bearing (see Chapter 7).
- Paint or spray the top half of the shell (11), the bottom half of the shell (13) and the shaft with
TECTYL 511.
- Assemble the bearing (see Chapter 8).
- Close all tapped holes with screw plugs.
- Seal the gaps between · shaft seal and housing
· shaft seal and shaft
by using a self
adhesive, permanent tape.
- Remove the top sight glass (5). Spray some anti
corrosive such as TECTYL 511 or VALVOLINE
into the bearing.
- Put a bag of dessicant (silicate gel) inside. The dessicant absorbs the humidity and prevents the
formation of condensation water inside the bearing.
- Close the bearing tight with the top sight glass (5).

In case the standstill period is longer than 1/2 year:

- Repeat the preservation procedures.
- Put a new bag of dessicant into the bearing.

In case the standstill period lasts more years:

- Dismantle the shells.
- Preserve and store the bearing parts.

11 Transport Protection

In case of a machine equipped with slide bearings of type EF:

- Carry out the corrosion protection as described in Chapter 10 and apply enough lubricant on
the working surfaces of the bearing.
- Secure the shaft against thrust and radial movements during transportation

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 EF with self lubrication

12 Glossary

Baffle With bearing types 10 and 20 the baffles are assembled externally in front of the shaft
seals. The baffle, made of reinforced polyamide, protects the bearing from dust and
water.

Rigid labyrinth seal The rigid labyrinth seal (type 20) is used with slide bearings type E with high oil
throughput.It corresponds to the protective system IP44 and is made of an aluminium
alloy.
The rigid labyrinth seal is built of two halves, flanged at the housing.The labyrinths that
wipe out the lubricant are arranged into two groups.The first two labyrinths , installed
inside keep back most of the lubricant. Five further labyrinths protect the bearing from
outside.They prevent the lubricant overflow and the ingress of impurities.The overflow
lubricant is collected into a chamber between the both groups of labyrinths.Through
the return bores the lubricant flows back into the bearing.

Spherical seating The spherical seating is a special feature enabling the alignment of the shell in the
housing.The shell is seated on two spherical seatings. The advantages of the spherical
seating are:
· easy at assembly
· good heat transfer from the shell to the housing
· suitable for such applications with high thrust or journal loads.

Dust flinger In the case of bearing types 10 and 20 a light alloy ring is clamped on the shaft in front
of the shaft.This ring fits into a groove in the seal carrier or the rigid labyrinth seal, thus
building a labyrinth. The labyrinth protects the shaft exit against low pressure that could
otherwise " absorb " the lubricant. Low pressure occurs for instance in the case of
rotating discs, such as couplings or cooling discs.

Floating labyrinth The floating labyrinth seal (type 10) in the seal carrier is used as a shaft seal in the case
seal of bearings type E operating under normal conditions. It prevents the lubricant and
lubricant mist coming out and the ingress of impurities. The floating seal has a high
capacity of resistance to wear. It is made of a high
performance, high temperature
stability and electrically insulated plastic material.The floating seal consists of two
halves held together by a garter spring. Both ends of the spring are hooked together. In
the case of slide bearings type EM the floating seal is mounted into a two
piece seal
carrier. The groove allows for radial movement of up to 1 mm. The seal is thus
insensitive to shaft radial displacement or deflection. The sealing effect is produced by
the baffles wiping off the lubricant from the shaft. The lubricant flows back into the
bearing via oil return opening.

Machine seal In the case of the flange mounted bearings, the machine seal reduces the influence of
positive and negative pressure in the machine thus preventing leakages at the inner
seal area. The space between the machine seal and the bearing housing must always
be vented to atmospheric pressure. The size of the gap between shaft and machine
seal influences the sealing effect.

Ó RENK AG Werk Hannover RH
EFEWI
E Version: 1 Juli, 2002 49

Instructions
For Installation and Operation

Slide Bearings TYPE EF

with self lubrication

RH - EFEEI - E – 07.02
Installation and Operation

RENK AKTIENGESELLSCHAFT
Werk Hannover
Weltausstellungsallee 21
D - 30539 Hannover
Telephone: (0511) 8601-0
Telefax: (0511) 8601-266
e-mail: [email protected]
http:\\www.renk.biz

All rights reserved. Copy or reproduction without prior permission of RENK Aktiengesellschaft Hannover
prohibited.

2 RH-EFEEI-E Version: 1 Juli, 2002/A RENK AG Werk Hannover

 EF with self lubrication

Contents

Bearing Coding ................................................................................................................................................5

General Drawing of the Slide Bearing EF with self lubrication ........................................................................7
General Drawing of the Loose Oil Ring ...........................................................................................................9
General Drawing of the Floating Labyrinth Seal with Seal Carrier ................................................................11
General Drawing of the Rigid Labyrinth Seal.................................................................................................13
General Drawing of the Baffle........................................................................................................................15
General Drawing of the Dust flinger...............................................................................................................17
1 Considerations for Use...........................................................................................................................19
2 Safety Instructions ..................................................................................................................................20
3 Preparatory Works ..................................................................................................................................21
3.1 Tools and equipment..........................................................................................................................21
3.2 Use of lifting equipment......................................................................................................................21
3.3 Dismantling of the bearing .................................................................................................................23
3.3.1 Dismantling of the shaft seal - outboard side .............................................................................23
3.3.2 Dismantling of the housing .........................................................................................................24
3.3.3 Dismantling of the shaft seal - machine-side..............................................................................24
3.4 Cleaning of the bearing ......................................................................................................................25
3.5 Checks ...............................................................................................................................................25
4 Assembly of the Bearing ........................................................................................................................26
4.1 Assembly of the the machine seal .....................................................................................................26
4.2 Fitting the bottom half of the housing into the machine shield...........................................................26
4.3 Fitting in the bottom half of the shell ..................................................................................................27
4.4 Assembly of the shaft seal - machine-side ........................................................................................28
4.5 Installation of the loose oil ring...........................................................................................................30
4.6 Fitting in the top half of the shell ........................................................................................................31
4.7 Assembly of the top half of the housing .............................................................................................33
5 Assembly of the Seals - Outboard Side ................................................................................................34
5.1 Floating labyrinth seal (Type 10)........................................................................................................34
5.2 Floating labyrinth seal with dust flinger (Type 11) .............................................................................38
5.3 Floating labyrinth seal with baffle ( Type 12) .....................................................................................39
5.4 Rigid labyrinth seal (Type 20) ............................................................................................................39
5.5 Rigid labyrinth seal with dust flinger (Type 21) ..................................................................................41
5.6 Rigid labyrinth seal with baffle (Type 22) ...........................................................................................41

RENK AG Werk Hannover RH-EFEEI-E Version: 1 Juli, 2002 A 3

Installation and Operation

6 Instructions for Assembly of Peripheral Equipment ...........................................................................42

6.1 Temperature measurement ...............................................................................................................42
6.2 Water supply ......................................................................................................................................42
7 Bearing Insulation ...................................................................................................................................42
8 Operation..................................................................................................................................................43
8.1 Filling up with lubricating oil ...............................................................................................................43
8.2 Trial run ..............................................................................................................................................44
9 Glossary ...................................................................................................................................................45

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 EF with self lubrication

Bearing Coding

RENK AG Werk Hannover RH-EFEEI-E Version: 1 Juli, 2002 A 5

Installation and Operation

n o p q r s

Type Housing Heat Dissipation Shape of Bore and Type of Thrust part Size - Diameter
Lubrication

E F - flange mounted N - natural cooling L - plain cylindrical bore with Q - without thrust part 9 80 D 100
bearing loose oil ring (non-locating bearing )
W - water cooling 11 100 D 125
(finned cooler in oil sump ) B - plain silding surfaces with oil
grooves (locating bearing) 14 125 D 160

E - taper land faces for one 18 160 D 200

sense of rotation
(locating bearing) 22 200 D 250

K - taper land faces for both 28 250 D 315

senses of rotation
(locating bearing)

Example for bearing coding:

n o p q r s
E F N L Q 22-200 Type EF slide bearing with flange mounted housing, natural cooling,
plain cylindrical bore with loose oil ring, non locating bearing without thrust part,
size 22, diameter 200.

Shaft seals Type 10 - floating labyrinth seal (IP 44)

Type 11 - floating labyrinth seal with dust flinger (IP 54)
Type 12 - floating labyrinth seal with baffle (IP 55)

Type 20 - rigid labyrinth seal (IP 44)

Type 21 - rigid labyrinth seal with dust flinger (IP 54)
Type 22 - rigid labyrinth seal with baffle (IP 55)

6 RH-EFEEI-E Version: 1 Juli, 2002 A © RENK AG Werk Hannover

 self lubrication

General Drawing of the

Slide Bearing EF

with self lubrication

RENK AG Werk Hannover RH-EFEE/WI-E Version: 1 Juli, 2002 7

 5 6 7 8 9

4
10

11

3 12

13
2
14

15
1
16

17
xxx

x
18
xxx

19

20

21

22

23

24

27 26 25
 1 Top half of the housing
2 Hole for positioning pin
3 Pin for positioning shell
4 Oil filling hole
5 Top sight glass
6 Eye bolt
7 Screw (not included in delivery)
8 Screw
9 Tapped hole ( in the top and bottom halves of the shell, up size 14 )
10 Machine seal
11 Top half of the shell
12 Screw (split line of the housing)
13 Bottom half of the shell
14 Spherical seating
15 Engraved number - shell
16 Spigot
17 Tapped hole
18 Screw (not included in delivery)
19 Screw (split line of the shell)
20 Engraved numbers - housing
21 Bottom half of the housing
22 Tapped hole for journal bearing temperature measurement
23 Oil sight glass
24 Tapped hole for oil sump temperature measurement
25 Outlet/Inlet cooling water (Type E.T..)
26 Cooler ( Type E.T..)
27 Hexagon head plug (Oil drain plug)
 self lubrication

General Drawing of the

Loose Oil Ring

RENK AG Werk Hannover RH-LSEE/WI-E Version: 1 Juli, 2002 A 9

33

34

35

36
33 Loose oil ring
34 Dowel pin
35 Hole
36 Screw
 self lubrication

General Drawing of the

Floating Labyrinth Seal

with Seal Carrier

RENK AG Werk Hannover RH-SSEE/WI-E Version: 1 Juli, 2002 A 11

 Bearing side
37

38
43

42

39

41

40

Outer view
47 44

46

45
37 Seal carrier - top half
38 Garter spring
39 Groove
40 Seal carrier - bottom half
41 Bottom half of the seal
42 Top half of the seal
43 Anti - rotation pin
44 Screw
45 Engraved number
46 Groove ( Type 11 )
47 Engraved number
 self lubrication

General Drawing of the

Rigid Labyrinth Seal

RENK AG Werk Hannover RH-KDEE/WI-E Version: 1 Juli, 2002 A 13

 48
49

54

50 (2x)

51

53

52
48 Rigid labyrinth seal - top half
49 Screw
50 Screw (split line)
51 Groove ( Type 21 )
52 Rigid labyrinth seal - bottom half
53 Engraved number
54 Engraved number
 self lubrication

General Drawing

Baffle

RENK AG Werk Hannover RH-DSEE/WI-E Version: 1 Juli, 2002 A 15

 55

56

57
55 Baffle - top half
56 Screw
57 Baffle - bottom half
 self lubrication

General Drawing of the

Dust Flinger

RENK AG Werk Hannover RH-LREE/WI-E Version: 1 Juli, 2002 A 17

 58

59 (2x)
58 Dust flinger
59 Screw (split line)
 EF with self lubrication

1 Considerations for Use

The instructions for installation and operation are addressed to qualified technical personnel
(fitters, mechanic installers, mechanical engineers).

Read these instructions carefully before starting assembly.

Slide bearings of type EF are almost universally used in the engineering industry. Therefore it is
not possible to provide detailed information on all possible types and range of applications for
these bearing types. For instance, the position of the connection points for supply and monitoring
equipment is determined by the place of application ( in the following called " installation " ). Please
keep ready the guidelines with the technical documentation before starting assembly and operation
of the slide bearings.

Additional technical documentation with detailed information is supplied in the case of special
design bearings. Please contact RENK Export or Domestic Department for supplementary
information on bearings. Please indicate the bearing coding and the full reference number, too.

Following indications should be observed when reading these instructions.

Safety instructions are marked as follows:

Caution !
Warning of dangers for personnel.
Example: Warning of injury

Attention!
Warning of damage for the bearing or installation.

Useful recommendations and additional information are framed.

EFW.. This is how chapters, instructions or recommendations are marked when referring to a single type
or size of a bearing.
Example: Slide bearing type EF with water cooler
- Instruction follows.

Beginning of an enumeration.

( ) This is how the different parts of a bearing as described in the general drawings ( numbers )
are marked in the text.

− Use the enclosed check-list before starting assembly or operation. Copies available on request.
− The check list provides the experienced mechanical fitters of RENK bearings with the
necessary instructions for installation and operation.

RENK AG Werk Hannover RH-EFEEI-E Version: 1 Juli, 2002 A 19

Installation and Operation

2 Safety Instructions

Danger!
The maintenance and inspection of the slide bearings should be carried out by:
persons nominated by the safety representative
persons correspondingly trained and instructed
persons with knowledge on appropriate standards, regulations and accident
prevention rules
persons with knowledge on first-aid measures and local rescue centers.

Warning of injury!
Before starting work on the bearing:
- Switch off the installation.
- Make sure the installation is not in operation.
Never lift or transport machines, etc.by the bearing eye bolts. These are only intended
for assembly and dismantling of the bearing !

Warning of injury!
Do not grab such heavy bearing parts as the housing during assembly or dismantling
work. This could result in bruising or injury to hands !

Attention!
All metal parts of a slide bearing consisting of top and bottom half such as the housing, shells,
shaft seals are marked by engraved numbers. Fit together only the parts with the same number.

Attention!
In case • the admissible bearing temperature exceeds 15 K
• inadmissible vibrations occur
• unusual noises or odours are noticed
monitoring equipment triggers alarm
shut down the installation and inform the maintenance personnel in charge.

Attention!
Do not operate the bearing below the transition speed values indicated in the bearing calculation,
thus avoiding inadmissible operating conditions, which could lead to damage to the bearing.

Attention!
Please observe our leaflet Technical Information No. 85 which refers to various sealing compounds
for extended technical applications.

20 RH-EFEEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 EF with self lubrication

3 Preparatory Works

3.1 Tools and equipment

− Following tools and equipment are necessary:

• Allan key set
• Wrenching key set
• Open-jawed spanner set
• Feeler gauges ( up 0,05 mm )
• Caliper gauge
• Emery paper, plain scraper
• Oil stone
• Lifting equipment
• Permanent sealing compound
• Clean (close weave) rags
• Oil with the viscosity indicated (see bearing type plate)
• Detergents
• Liquid screw locking compound ( e.g. LOCTITE 242 )
• Liquid sealing compound and Teflon-tape

3.2 Use of lifting equipment

Warning of injury!

Before transport or lifting check if the eye bolts are tight ! Insecure eye bolts could
result in bearing becoming loose.
Before moving the bearing by the eye bolts make sure that the screws at the split line
are tightened, otherwise the bottom half of the bearing could become detached.
Make sure that the eye bolts are not exposed to bending stress, otherwise the bolts
could break.

Follow exactly the instructions for the use of lifting equipment.

− Use lifting equipment for assembly or transport of the following items:

Transport/Assembly of: Use lifting equipment for the following bearing sizes

Whole bearing unit 9-28

Top half of the housing 14-28

Bottom half of the housing 11-28

Shells 14-28

RENK AG Werk Hannover RH-EFEEI-E Version: 1 Juli, 2002 A 21

Installation and Operation

Following steps are to be observed before using the lifting equipment:

Whole bearing unit

− Check if the screws are tight (12):

Bearing size 9 11 14 18 22 28

Torque [Nm] 69 69 170 330 570 1150

− Check if the eye bolts (6) are tight.

− Connect the lifting equipment to the eye bolts (6).

Top half of the housing

− Check if the eye bolts (6) are tight.
− Connect the lifting devices to the eye bolts (6).

Bottom half of the housing

− Screw two eye bolts (6) with suitable threads tight into the cross-placed opposite tapped holes
(17).

Bearing size 9 11 14 18 22 28

Tapped hole M 12 M 12 M 16 M 20 M 24 M 30

− Connect the lifting equipment to the eye bolts (6).

Shells
− Screw two eye bolts or screw hooks with suitable threads tight into the tapped holes (9):

Bearing size 14 18 22 28

Tapped hole M8 M 12 M 12 M 16

− Connect the lifting equipment to the eye bolts or to the screw hooks.

22 RH-EFEEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 EF with self lubrication

3.3 Dismantling of the bearing

Attention
Make sure that the work place and the parts to be assembled are clean. Contamination and
damage to the bearing, especially of the working surfaces, have a negative influence on the
operating quality and could lead to premature failure.

3.3.1 Dismantling of the shaft seal - outboard side

− Dismantle the shaft seals of the bearing. Proceed according to the sealing type:
Type Floating labyrinth seal (Type 10)
10 Floating labyrinth seal with dust flinger (Type 11)
Type
11 − Loosen and remove all screws (44).
− Simultaneously take away in axial direction both top half (37) and bottom half (40) of the seal
carrier from the housing.
− Lift off the top half of the seal carrier (37) and take out the floating labyrinth seal from the bottom
half of the seal carrier (40).
− Remove the protective cardboard (for transport protection) from the floating labyrinth seal.
Proceed as indicated for sizes • 9-11
•14-28
Size − Take hold of the floating labyrinth seal with both hands. Press out the protective cardboard with
9 -11 both thumbs.
Size − Take both halves of the seal (41), (42) by the split line. Pull both halves apart, till you can press
14-18 out the protective cardboard. Remove carefully by pressing along the edge of the split line.

Warning of injury!
During dismantling of the floating labyrinth seal hold on tight to the tensioned garter
spring (38) which otherwise could bounce back and lead to injury.

− Take both seal halves (41), (42) and pull them apart by approximately 20 mm.
− Open the garter spring (38).
Type Floating labyrinth seal with baffle (Type 12):
12
− Unscrew the top half of the baffle (55) and the bottom (57). To do so, loosen the screws (56).
− Further proceed as in the case of type 10 and 11seal.

Type Rigid labyrinth seal (Type 20)

20 Rigid labyrinth seal with dust flinger (Type 21)
Type − Untighten all screws (49) and remove them.
21 − Simultaneously remove in axial direction both top and bottom (48), (52) halves of the rigid
labyrinth seal.
− Remove the screws (50).
− Separate the top half of the rigid labyrinth seal (48) from the bottom half (52) and take out the
protective cardboard (for safe transport).

Type Rigid labyrinth seal with baffle (Type 22)

22
− Unscrew the top and bottom half (55), (57) of the baffle, by untightening the screws (56).
− Further proceed as in the case of types 20 and 21.

RENK AG Werk Hannover RH-EFEEI-E Version: 1 Juli, 2002 A 23

 Installation and Operation

3.3.2 Dismantling of the housing

− Unscrew the screws (12) and lift the top half of the housing (1).
− Take out both top (11) and bottom (13) halves of the shell from the bottom half (21) of the
housing.

Attention!
Do not damage the thrust and radial working surfaces!

− Unscrew the screws (19) and separate top and bottom half of the shell (11), (13) without using
any tools or other devices.

Attention!
If the bottom half of the shell (13) is provided with metal tabs do not remove them.They regulate the
oil level in the oil pockets.

EFW..
The cooler (26) is already assembled and does not have to be removed for cleaning purposes.

3.3.3 Dismantling of the shaft seal - machine-side

The machine side seal is of Type 10, floating labyrinth seal.

− Remove the floating labyrinth seal from the bottom half of the housing.
− Notice the anti-rotation pin at the split line of the bottom half of the housing.
− Remove the protective cardboard (for transport protection) from the floating labyrinth seal.
Proceed as indicated for sizes • 9-11
•14-28
Size − Take hold of the floating labyrinth seal with both hands. Press out the protective cardboard with
9 -11 both thumbs.
Size − Take both halves of the seal (41), (42) by the split line. Pull both halves apart, till you can press
14-18 out the protective cardboard. Remove carefully by pressing along the edge of the split line.

Warning of injury!
During dismantling of the floating labyrinth seal hold on tight to the tensioned garter
spring (38) which otherwise could bounce back and lead to injury.

− Take both seal halves (41), (42) and pull them apart by approximately 20 mm.
− Open the garter spring (38).

24 RH-EFEEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 EF with self lubrication

3.4 Cleaning of the bearing

Attention!
Use only non-aggressive detergents, such as for instance:
VALVOLINE 150.
Alcaline cleaning compounds (pH-value 6 to 9, short reaction time).

Warning of injury!
Please observe the instructions for the use of the detergents.

Attention!
Never use cleaning wool or fibrous cloth. Residues of such materials left in the bearing could lead
to excessive temperatures.

− Clean the following parts thoroughly, to remove all residues of preservation :

• inside the top half of the housing (1)
• inside the bottom half of the housing (21)
• all plain parts of the top and bottom half of the housing (1),(21)
• top half of the shell (11)
• bottom half of the shell (13)
• sealing surfaces of the top (37) and bottom (40) half of the seal carrier or of the rigid labyrinth
seal
• loose oil ring (33).

3.5 Checks

− Please check if there is any visible damage.Check the split line and the working surfaces in
particular.

The loose oil ring (33) should show absolutely no burrs or have no shoulders.
Insulated
Bearings − Check the insulating layer of the spherical seatings (14).

− If necessary, change the damaged parts.

RENK AG Werk Hannover RH-EFEEI-E Version: 1 Juli, 2002 A 25

Installation and Operation

4 Assembly of the Bearing

Attention!
Remove all impurities or other objects such as screws, nuts, etc. from inside the bearing.If left
inside they could lead to damage to the bearing. Cover up the opened bearing during work breaks.

Attention!
Carry out all assembly operations without making use of force.

Attention!
Secure all screws of the housing, flange and at the split line with a liquid screw locking compound
(e.g. LOCTITE 242).

4.1 Assembly of the the machine seal

Before assembly of the bearing screw the split and non-split machine seal (10) into the machine
shield. The non-split machine seal must be assembled before starting the assembly of the shaft.
− Place the machine seal with the recess onto the machine shield.
− In the case of a split machine seal insert the split line screws and tighten them hand tight.
− Tighten the screws (7) to the following torque rates:

Bearing size 9 11 14 18 22 28

Tapped hole M6 M6 M6 M8 M8 M8

Torque [Nm] 8 8 8 20 20 20

4.2 Fitting the bottom half of the housing into the machine shield

Attention!
The lifting equipment should not come in touch with the seal and working surfaces of the shaft.

− Lift the shaft high enough to have place for the assembly operations.
− Protect the shaft against unintended movement.
− Place the bottom half of the housing with the spigot (16) into the mounting recess of the
machine shield.
− Tighten the flange screws to the following torque rates.
− Use only 8.8 quality screws.

Bearing size 9 11 14 18 22 28

Suitable flange screws M 10 M 12 M 16 M 20 M 24 M 30

Torque [Nm] for µ tot 69 69 170 330 570 1150

(lightly oiled)

26 RH-EFEEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 EF with self lubrication

4.3 Fitting in the bottom half of the shell

EF..E Attention!
Mounting the bottom half of the shell (not marked with an arrow) correctly will ease the assembly of
the top half shell (marked with an arrow) (see chapter 4.6).

− Apply some lubricant to the spherical seating (14) in the bottom half of the housing (21) and to
the working surfaces of the shaft. Use the same type of lubricant as indicated for bearing
operation
( see type plate ).
− Place the bottom half of the shell (13) on the working surface of the shaft. Turn the bottom half
of the shell (13) into the bottom half of the housing (21) with the split line surfaces of both halves
in true alignment.

In case the bottom half of the shell doesn`t turn in easily, check the position of the shaft and the
alignment of the housing

EF..B, Attention!
EF..K, These operations should be carried out most carefully. The thrust parts of the bottom shell must
EF..E not be damaged.

− Lower down the shaft till it sits on the bottom half of the shell (13).

RENK AG Werk Hannover RH-EFEEI-E Version: 1 Juli, 2002 A 27

Installation and Operation

4.4 Assembly of the shaft seal - machine-side

The machine-side shaft seal is as standard, a floating labyrinth seal. The integrated seal groove is
in the top and bottom halves of the housing.

Warning of injury!
During assembly hold the garter spring ends securely to avoid them suddenly
releasing and causing possible injury !

Check the movement of the floating labyrinth seal on the shaft in the seal area outside the housing.
− Put the garter spring (38) around the shaft and hook both ends into each other.
− Put both halves of the seal (41),(42) in their place on the shaft.
− Put the garter spring (38) into the groove (39).
− Turn the floating labyrinth seal on the shaft.

Attention!
The floating labyrinth seal should turn easily on the shaft. A jammed seal could lead to overheating
during operation and even to shaft wear.
If the floating labyrinth seal jams,
- dismantle the seal and
- remove the worn parts of the seal carefully, by using emery paper or a plain scraper.

− Dismantle the floating labyrinth seal.

− Apply sealing compound to the guide surfaces of the integrated seal groove in the bottom half of
the housing.

Illustration 1: Application of sealing compound to the integrated seal groove

28 RH-EFEEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 EF with self lubrication

− Apply a uniform layer of sealing compound to the guide surfaces and to the split line surfaces of
both halves of the seal (41), (42).

Illustration 2: Application of sealing compound to the floating labyrinth seal

Please observe the instructions for the use of sealing compound.

− Place the bottom half of the seal (41)) with the labyrinths onto the shaft.
− The oil return holes at the bearing side must be clean and open.
− Turn the seal in opposite direction from the anti-rotation pin into the groove of the housing until
the split lines of the bottom half of the housing and the bottom half of the seal match each other.
− Remove the residues of sealing compound.
− Push the spring hook into the integrated groove between the bottom half of the housing and the
seal until both ends jut out from the split line.
− Place the top half of the seal with the cam facing the inside of the bearing on the bottom half of
the seal.
− Stretch the garter spring till both ends can be hooked.

RENK AG Werk Hannover RH-EFEEI-E Version: 1 Juli, 2002 A 29

Installation and Operation

4.5 Installation of the loose oil ring

− Open both split lines of the loose oil ring (33) by untightening and removing the screws (36).
Separate both halves of the loose oil ring (33) carefully without using any tools or other devices.

I II

33

33 33

36

Illustration 3: Opening of the loose oil ring

− Place both halves of the loose oil ring into the shell groove encircling the shaft. Press the
positioning pin (34) of each split line into the corresponding hole (35).
− Adjust both halves of the loose oil ring till the split lines match each other.

21
34

33

33 13

Illustration 4: Installation of the loose oil ring

− Tighten the screws (36) to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 1,4 1,4 1,4 2,7 2,7 2,7

30 RH-EFEEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 EF with self lubrication

4.6 Fitting in the top half of the shell

− Apply some lubricant to the working surfaces of the shaft. Use the same type of lubricant as
indicated for bearing operation (see type plate).
− Check if the engraved number (15) on the bottom half of the shell corresponds with the
engraved number (15) on the top half of the shell.
− Place the top half of the shell (11) on the shaft; both engraved numbers(15) should be on one
side.

Attention!
An incorrectly placed shell could jam the shaft thus leading to the damage of both shaft and
bearing.

EF..B, Attention!
EF..K, Place the top half of the shell carefully on the shaft. The thrust parts of the top half of the shell
EF..E should not be damaged.

insulated In the case of bearings arranged for insulation monitoring, connect the black cable for insulation
bearings
monitoring to the shell.
According to the bearing type, there are two possibilities of connection.
1. The black cable is provided with a cable connector.
− Plug the cable with the cable connector into the counterpart available on the top of the shell.
− Lead the cable through the cable gland in the bottom half of the housing and out of the bearing.
− Tighten the cable gland oil-tight.
2. The black cable is provided with an eyelet.
− Fasten the cable with the eyelet to the split line of the shell, by using one of the shell joint bolts.
− Lead the cable through the cable gland in the bottom half of the housing and out of the bearing.
− Tighten the cable gland oil-tight.

− Tighten up the screw (19) to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 8 8 20 69 69 170

− Check the split line of the shell by using a feeler gauge. The split line gap should be less than
0,05 mm. If the split line is greater than this, dismantle both top (11) and bottom (13) halves of
the shell. Rework the split line surfaces of the top (11) and bottom (13) half of the shell with an
oil stone.
− Check the mobility of the loose oil ring (33).
Marine A guide bush in the top half of the shell secures the function of the loose oil ring.
bearings
− Check the mobility of the loose oil ring (33) in the guide bush.

RENK AG Werk Hannover RH-EFEEI-E Version: 1 Juli, 2002 A 31

 Installation and Operation

EF..E Shells with taper land faces suitable only for one direction of rotation are marked with an arrow on
the top half shell, which indicates the sense of rotation of the shaft.
The arrow indicates the allowed direction of shaft rotation after completion of the bearing assembly.
− Before mounting the top half of the housing check that the proposed direction of rotation of the
shaft corresponds to the direction indicated by the arrow on the top half of the shell.
− If the directions match, continue the assembly of the bearing.
− If the directions do not match, the shell must be disassembled, re-aligned and mounted again.

Attention!
A wrongly placed shell, without observance of the direction of rotation of the shaft, impairs the
operational safety of the bearing.

32 RH-EFEEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 EF with self lubrication

4.7 Assembly of the top half of the housing

− Check the true alignment of the split lines of the shell (11), (13) and bottom (21) half of the
housing.

The positioning pin (3) in the top half of the housing fits in the corresponding hole (2) in the shell.

− Check if the engraved numbers (20) on the top and bottom halves of the housing correspond.
− Clean the split line surfaces of the top and bottom halves of the housing.
− Apply seal compound to the whole surface of the split line of the bottom half (21) of the housing.

Please observe the instructions for the use of sealing compound.

− Place the top half of the housing carefully into the machine shield, without touching the seals or
the shell.
− Lower the top half of the housing (1) vertically on the bottom half of the housing (21). Lower the
top half of the housing (1) till the split line of the housing is not visible any more.
− Gently hit the bottom half of the housing (21) with a nylon hammer, thus ensuring the alignment
of the spherical seating.
− Insert the screws (12). Tighten them hand-tight.
− Insert the screws (8). Tighten them to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 69 69 170 330 570 1150

− Insert the screws (12). Tighten them crosswise to the same torque rates.
insulated Insulation monitoring
bearings
In the case of electric insulated bearings provided with insulation monitoring, the cable coming out
of the housing must be connected in a professional manner.
According to the type supplied, please follow the assembly instructions given below.
a) The cable is very short and provided with a further cable connector at the end of it.
This cable is ready for connection to the housing.
The bottom half of the housing is provided with the counterpart.
− Plug the cable connector into the counterpart.

Attention!
This connection bypasses the electrical insulation of the bearing.
In the case of electric machines, make sure at least one bearing is electrically insulated.

To check the electrical insulation, interrupt the connection cable - housing. Check the electrical
resistance with a suitable measuring instrument. Make sure that both bearings and the coupling
are electrically insulated.
b) The cable has a free end. In this case the customer has to make the connection.

Attention!
If only one bearing is insulated, the end of the cable must not be earthed.

Any further connection depends on the customer’s requirements related to the insulation
monitoring and can not therefore be described here.

RENK AG Werk Hannover RH-EFEEI-E Version: 1 Juli, 2002 A 33

 Installation and Operation

5 Assembly of the Seals - Outboard Side

− Assemble the outboard side seals.

Proceed according to the seal type used.
• Floating labyrinth seal (Type 10) Chapter 5.1
• Floating labyrinth seal with dust flinger (Type 11) Chapter 5.2
• Floating labyrinth seal with baffle (Type 12) Chapter 5.3
• Rigid labyrinth seal (Type 20) Chapter 5.4
• Rigid labyrinth seal with dust flinger (Type 21) Chapter 5.5
• Rigid labyrinth seal with baffle (Type 22) Chapter 5.6

Type 5.1 Floating labyrinth seal (Type 10)

10
Warning of injury!
During assembly hold the garter spring ends securely to avoid them suddenly
releasing and causing possible injury !

Check the movement of the floating labyrinth seal on the shaft.

− Put the garter spring (38) around the shaft and hook both ends into each other.
− Put both halves of the seal (41),(42) in their place on the shaft.
− Put the garter spring (38) into the groove (39).
− Turn the floating labyrinth seal on the shaft.

Attention!
The floating labyrinth seal should turn easily on the shaft. A jammed seal could lead to overheating
during operation and even to shaft wear.
If the floating labyrinth seal jams,
- dismantle the seal and
- remove the worn parts of the seal carefully, by using emery paper or a plain scraper.

− Dismantle the floating labyrinth seal.

34 RH-EFEEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 EF with self lubrication

− Apply a uniform layer of sealing compound to the guide surfaces and to the split line surfaces of
both halves of the seal (41), (42).

Please observe the instructions for the use of sealing compound.

Illustration 5: Application of sealing compound to the floating labyrinth seal

− Press the bottom half of the seal (41) against the shaft.
− Place the top half of the seal (42) on the shaft and align both halves of the seal to each other.
− Place the garter spring (38) into the groove (39) and stretch until both ends can be hooked.

43 42 1

38 41 21

Illustration 6: Assembly of the floating labyrinth seal

RENK AG Werk Hannover RH-EFEEI-E Version: 1 Juli, 2002 A 35

Installation and Operation

− Place in true alignment the split line of the floating labyrinth seal and the split line of the seal
carrier.
− Check that both engraved numbers (45) and (47) on top and bottom halves of the seal carrier
(37), (40) correspond.
− Clean the following parts:
• the seal surfaces of the top (37) and bottom (40) half ofthe seal carrier (the groove of the
floating labyrinth seal, the flange surfaces)
• the split line surfaces of the top (37) and bottom half (40) of the seal carrier
• the flange surfaces of the housing.
− Apply a uniform layer of sealing compound to:
• the lateral surfaces of the groove at the top (37) and bottom half (40) of the seal carrier
• the flange surfaces of the top (37) and bottom (40) half of the seal carrier
• the split line surfaces of the bottom half of the seal carrier (40).

Please observe the instructions for the use of sealing compound.

Ilustration 7: Application of sealing compound to the seal carrier

36 RH-EFEEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 EF with self lubrication

− Place the top half of the seal carrier (37) on the top half of the seal (42). Press the bottom half
(40) of the seal carrier against it. Push the shaft seal completely into the housing.

37

43

42

Illustration 8 Assembly of the seal carrier

− Place in true alignment the split lines of the seal carrier and the housing.
− Tighten up the screws (44) to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 8 8 8 20 20 20

RENK AG Werk Hannover RH-EFEEI-E Version: 1 Juli, 2002 A 37

 Installation and Operation

Type
5.2 Floating labyrinth seal with dust flinger (Type 11)
11
− Assemble the floating labyrinth seal with dust flinger as described in Chapter 5.1, Floating
labyrinth seal type 10.
− Place both halves of the dust flinger (58) in front of the shaft seal around the shaft. Loosely
screw in the screws (59).

58 37

e 46

Illustration 9: Clearance between dust flinger and seal carrier

EF..Q − Push the dust flinger (58) into the groove (46) of the seal carrier.
− Set the clearance "e" at the following figure around the whole unit:

maximum longitudinal extension of the shaft in operation + 1 mm

(Parameters indicated in the Technical Documentation of the Installation).
− Tighten up both screws (59) to the following torque rates:

Seal diameter [mm] 80-140 >140

Torque [Nm] 7 18

EF..B, − Push the dust flinger (58) into the groove (46) of the seal carrier.
EF..K, − Set the clearance "e"at 1 mm around the whole unit.
EF..E − Tighten both screws (59) to the following torque rates:

Seal diameter [mm] 80-140 >140

Torque [Nm] 7 18

38 RH-EFEEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 EF with self lubrication

Type 5.3 Floating labyrinth seal with baffle ( Type 12)

12
− Assemble the floating labyrinth seal with baffle as described in Chapter 5.1, type10.
− Apply a uniform layer of sealing compound to the flange surfaces of the top half (55) and bottom
half (57) of the baffle.
− Screw the top half of the baffle (55) onto top half of the seal carrier (37)
the bottom half of the baffle (57) onto bottom half of the seal carrier (40).
− Tighten the screws (56) to the following torque rates:

Seal diameter [mm] 80-140 >140

Torque [Nm] 4 10

Type 5.4 Rigid labyrinth seal (Type 20)

20
− Check if the engraved numbers (53) and (54) on the bottom half (52) and top half (48) of the
rigid labyrinth seal correspond.
− Clean
• the flange surfaces of the top half (48) and bottom half (52) of the rigid labyrinth seal
• the split line surfaces of the top half (48) and bottom half (52) of the rigid labyrinth seal
• the flange surfaces of the housing.
− Apply a uniform layer of sealing compound to the following parts:
• the flange surfaces of the top (48) and bottom half (52) of the rigid labyrinth seal
• the split lines of the bottom half (52) of the rigid labyrinth seal.

Illustration 10: Application of sealing compound to the rigid labyrinth seal

RENK AG Werk Hannover RH-EFEEI-E Version: 1 Juli, 2002 A 39

Installation and Operation

− Place the top half (48) of the rigid labyrinth seal on the shaft and press slightly the bottom half
(52) of the rigid labyrinth seal from below against it. Lightly push the rigid labyrinth seal
completely into the housing.
− Tighten the screws (50).
− Place in parallel alignment the split line of the rigid labyrinth seal and the split line of the
housing. Press the rigid labyrinth seal slightly from below against the shaft. Adjust the rigid
labyrinth seal in such a way that the clearance "f" between the shaft and the rigid labyrinth seal
at both split lines has the same figure.

1 48

f f

21 52

Illustration 11: Alignment of the rigid labyrinth seal

− Tighten the screws (49) to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 8 8 8 20 20 20

40 RH-EFEEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 EF with self lubrication

Type
5.5 Rigid labyrinth seal with dust flinger (Type 21)
21
− Assemble the rigid labyrinth seal with dust flinger as described in Chapter 5.4, type 20.
− Place both halves of the dust flinger (58) round the shaft, in front of the rigid labyrinth seal.
Mount both screws (59) loose.

58 48

e
51

Illustration 12: Clearance between dust flinger and rigid labyrinth seal

EF..Q − Push the dust flinger (58) into the groove (51) of the rigid labyrinth seal.
− Set the clearance "e" at the following figure around the whole unit.

maximum longitudinal extension of the shaft in operation + 1 mm

(Parameters are indicated in the Technical Documentation of the Installation).
− Tighten both screws (59) to the following torque rates:

Seal diameter[mm] 80-140 >140

Torque [Nm] 7 18

EF..B, − Push the dust flinger (58) into the groove (51) of the rigid labyrinth seal.
EF..K, − Set the clearance "e" at 1 mm around the whole unit.
EF..E − Tighten both screws (59) to the following torque rates:

Seal diameter [mm] 80-140 >140

Torque [Nm] 7 18

Type 5.6 Rigid labyrinth seal with baffle (Type 22)

22
− Assemble the rigid seal with baffle as described in Chapter 5.4, type 20.
− Apply a uniform layer of sealing compound to the flange surfaces of the top half (55) and bottom
half (57) of the baffle.
− Screw the top half of the baffle (55) to the top half (48) of the rigid labyrinth seal
the bottom half of the baffle (57) to the bottom half (52) of the rigid labyrinth seal.
− Tighten the screws (56) to the following torque rates:

Seal diameter [mm] 80-140 >140

Torque [Nm] 4 10

RENK AG Werk Hannover RH-EFEEI-E Version: 1 Juli, 2002 A 41

 Installation and Operation

6 Instructions for Assembly of Peripheral Equipment

6.1 Temperature measurement

− Fix suitable thermo sensors:

• into one of the tapped holes (22) for temperature measurements of the journal parts
• into one of the tapped holes (24) for temperature measurements of the oil sump

Proceed as follows:
− Take out the screw plugs from the tapped holes.
− Place the thermo sensor into the bore by using Teflon tape or sealing compound.
− Connect the thermo sensor at the temperature monitoring equipment of the installation (see the
Technical Documentation of the Installation for connecting and adjustement).

EFW.. 6.2 Water supply

Following requirements should be observed before connecting the cooler (26):

• water velocity of maximum 1,5 m/s in the cooling water inlet
• water pressure of maximum 5 bar
• adjusting tap on inlet
• outlet of cooling water is under no pressure.
The direction of the cooling water passage in the cooler (26) is arbitrary.

7 Bearing Insulation

These bearings are delivered insulated. The electrical insulation is guaranteed by:
• plastic coating of the spherical seatings (14)
• shaft seals made out of non-conducting materials
• insulated positioning pin (3)
• insulated screwed connections for thermometers.
− Mark the insulated bearing with the delivered plate " Insulated shells". Mount the plate at a
visible place by using two grooved drive studs.

42 RH-EFEEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 EF with self lubrication

8 Operation

8.1 Filling up with lubricating oil

Attention!
Make sure that no impurities get into the bearing.

− Tighten all screw plugs in the tapped holes (22), (24), (27) to the necessary torque rates:

Screw plug threads G 3/8 G 1/2 G 3/4 G1 G 1 1/4 G 1 1/2 G2 G 2 1/2

Torque [Nm] for plugs 30 40 60 110 160 230 320 500

with moulded on plastic
seal

Torque [Nm] for plugs 34 60 85 130 240 300 330 410

with elastic seal

− Check that:
• the top sight glass (5) is tight, the screws should be hand-tight.
• the oil sight glass (23) is tight, the screws should be hand-tight.
In the case thermo sensors or / and oil sump thermometers are used:
− Check that they are tight (according to the manufacturer's instructions).
− Remove the screw plugs from the oil filling hole (4).
− Use a lubricant with the viscosity indicated on the bearing type plate. Fill the lubricant through
the oil filling hole (4) up to the middle point of the oil sight glass (23).
The oil level limits are as follows:
minimum oil level: bottom of the oil sight glass
maximum oil level: top of the oil sight glass

Attention!
Not enough lubricant leads to temperature rises and thus to damage to the bearing.
Too much lubricant leads to leakages. In the case of bearings with lubrication by loose oil
ring too much lubricant could have a considerable breaking effect on the oil rings,
thus leading to damage to the bearing.

− Tighten the screw plug into the oil filling hole (4) to the following torque rates:

Bearing size 9 11 14 18 22 28

Torque [Nm] 30 30 30 40 60 60

− Remove the protective layer from the top sight glass (4).

RENK AG Werk Hannover RH-EFEEI-E Version: 1 Juli, 2002 A 43

 Installation and Operation

8.2 Trial run

− Before the trial run, check:

• The oil level (see Chapter 8.1)
• that the temperature monitoring equipment works
EFW.. • that the water cooling installation works.

The bearing is ready for operation.

− Supervise the bearing during the trial run (5-10 operating hours).
Pay special attention to:
• oil level (see Chapter 8.1)
• bearing temperature
• sliding noises of the shaft seals
• tightness
• occurrence of inadmissible vibrations.

Attention!
If the bearing temperature exceeds the calculated value by 15 K (see Bearing calculation) stop the
installation immediately. Carry out an inspection of the bearing as described under Instructions for
Maintenance and Inspection of the Slide Bearings Type EF with self lubrication.

44 RH-EFEEI-E Version: 1 Juli, 2002 A RENK AG Werk Hannover

 EF with self lubrication

9 Glossary

Baffle With bearing types 10 and 20 the baffles are assembled externally in front of the shaft
seals. The baffle, made of reinforced polyamide, protects the bearing from dust and
water.

Rigid labyrinth seal The rigid labyrinth seal (type 20) is used with slide bearings type E with high oil
throughput.It corresponds to the protective system IP44 and is made of an aluminium
alloy.
The rigid labyrinth seal is built of two halves, flanged at the housing.The labyrinths that
wipe out the lubricant are arranged into two groups.The first two labyrinths , installed
inside keep back most of the lubricant. Five further labyrinths protect the bearing from
outside.They prevent the lubricant overflow and the ingress of impurities.The overflow
lubricant is collected into a chamber between the both groups of labyrinths.Through the
return bores the lubricant flows back into the bearing.

Spherical seating The spherical seating is a special feature enabling the alignment of the shell in the
housing.The shell is seated on two spherical seatings. The advantages of the spherical
seating are:
• easy at assembly
• good heat transfer from the shell to the housing
• suitable for such applications with high thrust or journal loads.

Dust flinger In the case of bearing types 10 and 20 a light alloy ring is clamped on the shaft in front
of the shaft.This ring fits into a groove in the seal carrier or the rigid labyrinth seal, thus
building a labyrinth. The labyrinth protects the shaft exit against low pressure that could
otherwise " absorb " the lubricant. Low pressure occurs for instance in the case of
rotating discs, such as couplings or cooling discs.

Floating labyrinth The floating labyrinth seal (type 10) in the seal carrier is used as a shaft seal in the case
seal of bearings type E operating under normal conditions. It prevents the lubricant and
lubricant mist coming out and the ingress of impurities. The floating seal has a high
capacity of resistance to wear. It is made of a high-performance, high temperature
stability and electrically insulated plastic material.The floating seal consists of two
halves held together by a garter spring. Both ends of the spring are hooked together. In
the case of slide bearings type EM the floating seal is mounted into a two-piece seal
carrier. The groove allows for radial movement of up to 1 mm. The seal is thus
insensitive to shaft radial displacement or deflection. The sealing effect is produced by
the baffles wiping off the lubricant from the shaft. The lubricant flows back into the
bearing via oil return opening.

Machine seal In the case of the flange mounted bearings, the machine seal reduces the influence of
positive and negative pressure in the machine thus preventing leakages at the inner
seal area. The space between the machine seal and the bearing housing must always
be vented to atmospheric pressure. The size of the gap between shaft and machine
seal influences the sealing effect.

RENK AG Werk Hannover RH-EFEEI-E Version: 1 Juli, 2002 A 45

 WERK
HANNOVER Spare Parts List
Part Designation RENK ID - No. Qty.

BEARING EFULK 22-225

DRAWING-NO.: 27127608 A

1 HOUSING EF22 730507 1

2 HEXAGON SOCKET HEAD CAP SCREW M24X90 350943 4
3 RING BOLT M24 158013 2
4 POSITIONING PIN 22 350913 1
5 SIGHT GLASS BSP11/2“ 694050 1
6 OIL SIGHT GLASS BSP2“ 725953 1
7 SCREW PLUG BSP2“ 351010 1
8 SCREW PLUG BSP3/4“ 351006 4
9 SCREW PLUG BSP1/2“ 351005 4
10 SHELL EZLK 22-225 726098 1
11 HEXAGON SOCKET HEAD CAP SCREW M12X35 346924 2
12 LOOSE OIL RING 22-1 698762 1
13 HEAD SCREW M5X20 142900 2
14 LABYRINTH SEAL 250-R 758532 1
15 LABYRINTH SEAL 250-R 758532 1
16 SEAL CARRIER 22-250 700102 1
17 HEXAGON SOCKET HEAD CAP SCREW M8X20 158532 8
18 BAFFLE 250 140458 1
19 HEXAGON SOCKET HEAD CAP SCREW M6X30 142948 8
20 WASHER 6 350445 8
21 OIL RING GUIDE 22 350947 1
22 COUNTERSUNK FLAT HEAD SCREW M5X12 184333 2

Filename Page Si. Date Appr. Date RENK ID - No Revisions

L787808e 1/1 Be 11.11.13 L787808 A
 WERK
HANNOVER Spare Parts List
Part Designation RENK ID - No. Qty.

BEARING EFNLQ 14-125

DRAWING-NO.: 27133108 A

1 HOUSING EF14 744139 1

2 HEXAGON SOCKET HEAD CAP SCREW M16X50 338376 4
3 RING BOLT M16 157995 2
4 POSITIONING PIN 14 350911 1
5 SIGHT GLASS G11/2 694050 1
6 OIL SIGHT GLASS BSP11/2” 730102 1
7 SCREW PLUG BSP11/2” 351009 1
8 SCREW PLUG BSP1/2” 351005 6
9 SCREW PLUG BSP3/8” 351004 2
10 SHELL EZLQ 14-125 698487 1
11 HEXAGON SOCKET HEAD CAP SCREW M8X25 158563 2
12 LOOSE OIL RING 14-1 554633 1
13 HEXAGON SOCKET HEAD CAP SCREW M4X12 140300 2
14 LABYRINTH SEAL 160-R 757101 1
15 LABYRINTH SEAL 140 350019 1
16 SEAL CARRIER 14-140 797055 1
17 HEXAGON SOCKET HEAD CAP SCREW M6X16 142924 6
18 OIL RING GUIDE 14 743321 1
19 COUNTERSUNK FLAT HEAD SCREW M5X12 184333 2

Filename Page Si. Date Appr. Date RENK ID - No Revisions

L796796e 1/1 Bi 10.11.10 L796796 A
Schmierstoffe für RENK-Gleitlager
Empfehlung für Mineralöle

Lubricants for RENK Slide Bearings
Recommendation for Mineral Oils
 ISO Dynamische Viskosität Dichte
Produkt
Viskositätsklasse [mPa s] [kg/m³]

Class of Viscosity Dynamic Viscosity Density

Product
ISO [mPa s] [kg/m³]

40 °C 100 °C 15 °C
22
32 28 4,3 870 Motanol HE 32
Aral Aktiengesellschaft
Neuhöfer Brückenstr. 127-152
46 39 5,6 873 Degol CL 46 T
D-21107 Hamburg 68 60 7,2 882 Degol CL 68 T
Tel.: +49(0)40-30235-0 100 86 9,1 878 Degol CL 100 T
Fax : +49(0)40- 30235-893
www.aral-lubricants.de 150 130 12 887 Degol CL 150 T
220 190 16 888 Degol CL 220 T
320 280 19 894 Degol CL 320 T

ISO Dynamische Viskosität Dichte

Produkt
Viskositätsklasse [mPa s] [kg/m³]

Class of Viscosity Dynamic Viscosity Density

Product
ISO [mPa s] [kg/m³]

40 °C 100 °C 15 °C
22
32 27 4,4 871 Energol RC-R 32
Deutsche BP AG 46 38 5,4 873 Energol RC-R 46
Neuhöfer Brückenstr. 127-152
D-21107 Hamburg
68 58 7,1 878 Energol RC 68
Tel.: +49(0)2161-909-30 100 78 8,5 880 Energol RC 100
www.bp.com 150 130 12 888 Energol RC 150
220 190 15 888 Energol CS-HB 220
320

ISO Dynamische Viskosität Dichte

Produkt
Viskositätsklasse [mPa s] [kg/m³]

Class of Viscosity Dynamic Viscosity Density

Product
ISO [mPa s] [kg/m³]

40 °C 100 °C 15 °C
22
Chevron Global Lubricants 32 27 4,7 880 Caltex Regal R&O 32
Texaco Deutschland GmbH
Jungfernstieg 49
46 39 5,8 880 Caltex Regal R&O 46
D-20354 Hamburg 68 57 7,4 880 Caltex Regal R&O 68
Tel: +49(0)40 35003641 100 88 9,5 880 Caltex Regal R&O 100
Fax: +49(0)40 35003699
www.caltex.com 150
220
320

2
 ISO Dynamische Viskosität Dichte
Produkt
Viskositätsklasse [mPa s] [kg/m³]

Class of Viscosity Dynamic Viscosity Density

Product
ISO [mPa s] [kg/m³]

40 °C 100 °C 15 °C
22 19 3,8 872 Hyspin VG 22
32 28 4,7 872 Hyspin VG 32
Castrol Industrie GmbH 46 40 6,0 876 Hyspin VG 46
Erkelenzer Straße 20
D-41179 Mönchengladbach
68 60 7,8 881 Hyspin VG 68
Tel.:+47(0)2161 909-30 100 89 9,8 885 Hyspin VG 100
www.castroladvantage.com 150 130 13 886 Hyspin VG 150
220
320

ISO Dynamische Viskosität Dichte

Produkt
Viskositätsklasse [mPa s] [kg/m³]

Class of Viscosity Dynamic Viscosity Density

Product
ISO [mPa s] [kg/m³]

40 °C 100 °C 15 °C
22 20 3,8 854 Chevron AIO 22
Chevron Global Lubricants 32 26 4,5 859 Chevron AIO 32
Texaco Deutschland GmbH
Jungfernstieg 49
46 38 5,6 865 Chevron AIO 46
D-20354 Hamburg 68 56 7,3 870 Chevron AIO 68
Tel: +49(0)40 35003641 100 83 9,4 872 Chevron AIO 100
Fax: +49(0)40 35003699
www.chevron.com 150 130 12 877 Chevron AIO 150
220 190 17 884 Chevron AIO 220
320 270 21 890 Chevron AIO 320

ISO Dynamische Viskosität Dichte

Produkt
Viskositätsklasse [mPa s] [kg/m³]

Class of Viscosity Dynamic Viscosity Density

Product
ISO [mPa s] [kg/m³]

40 °C 100 °C 15 °C
22
32 28 4,6 860 Teresstic T 32
Esso Deutschland GmbH
Kapstadtring 2
46 40 5,9 870 Teresstic T 46
D-22297 Hamburg 68 59 7,4 870 Teresstic T 68
Tel.: +49(0)40 6393-0 100 88 9,3 880 Teresstic T 100
Fax: +49(0)40 6393-1578
www.exxonmobil.com 150 130 12 890 Nuto 150
220 200 17 890 Nuto 220
320 290 22 900 Nuto 320

3
 ISO Dynamische Viskosität Dichte
Produkt
Viskositätsklasse [mPa s] [kg/m³]

Class of Viscosity Dynamic Viscosity Density

Product
ISO [mPa s] [kg/m³]

40 °C 100 °C 15 °C
22 18 3,5 855 Renolin DTA 22
FUCHS Europe 32 28 4,8 874 Renolin DTA 32
Schmierstoffe GmbH 46 40 6,2 874 Renolin DTA 46
Friesenheimer Str. 15
D-68169 Mannheim
68 59 7,6 882 Renolin DTA 68
Tel: +49(0)621-3701-0 100 88 10 881 Renolin DTA 100
Fax: +49(0)621-3701-502 150 130 13 886 Renolin DTA 150
www.fuchs-europe.de
220 200 17 893 Renolin DTA 220
320 290 22 898 Renolin DTA 320

ISO Dynamische Viskosität Dichte

Produkt
Viskositätsklasse [mPa s] [kg/m³]

Class of Viscosity Dynamic Viscosity Density

Product
ISO [mPa s] [kg/m³]

40 °C 100 °C 15 °C
22 19 3,3 870 TURMOFLUID CL 22
32 28 4,1 877 TURMOFLUID CL 32
LUBRICANT CONSULT GmbH
Gutenbergstr. 13
46 40 5,8 875 TURMOFLUID CL 46
D-63477 Maintal 68 59 7,5 883 TURMOFLUID CL 68
Tel.: +49(0)6109-7650-0 100 88 10 890 TURMOFLUID CL 100
Fax: +49(0)6109-7650-51
www.lubcon.com 150 130 13 891 TURMOFLUID CL 150
220 190 17 892 TURMOFLUID CL 220
320 280 21 897 TURMOFLUID CL 320

ISO Dynamische Viskosität Dichte

Produkt
Viskositätsklasse [mPa s] [kg/m³]

Class of Viscosity Dynamic Viscosity Density

Product
ISO [mPa s] [kg/m³]

40 °C 100 °C 15 °C
22
32 26 4,7 850 DTE Oil Light
Esso Deutschland GmbH
Kapstadtring 2
46 38 5,8 870 DTE Oil Medium
D-22297 Hamburg 68 57 7,6 870 DTE Oil Heavy Medium
Tel.: +49(0)40 6393-0 100 84 9,6 880 DTE Oil Heavy
Fax: +49(0)40 6393-1578
www.exxonmobil.com 150 130 13 890 DTE Oil Extra Heavy
220 190 17 890 DTE Oil BB
320 270 21 900 DTE Oil AA

4
 ISO Dynamische Viskosität Dichte
Produkt
Viskositätsklasse [mPa s] [kg/m³]

Class of Viscosity Dynamic Viscosity Density

Product
ISO [mPa s] [kg/m³]

40 °C 100 °C 15 °C
22 19 3,5 865 Morlina 22
Shell 32 27 5,2 832 Turbo GT 32
Deutschland Schmierstoff 46 40 5,6 875 Morlina 46
GmbH
D-22284 Hamburg
68 58 7,3 878 Morlina 68
Tel.: +49(0)40-3003-8859 100 87 9,3 881 Morlina 100
Fax: +49(0)40-6324-5721 150 130 13 887 Morlina 150
www.shell.com
220 190 15 891 Morlina 220
320

ISO Dynamische Viskosität Dichte

Produkt
Viskositätsklasse [mPa s] [kg/m³]

Class of Viscosity Dynamic Viscosity Density

Product
ISO [mPa s] [kg/m³]

40 °C 100 °C 15 °C
22
Statoil Lubricants 32 29 4,8 872 Turbway 32
Svenska Statoil AB 46 40 6,0 876 Turbway 46
Torkel Knutssonsgatan 24
S-118 88 Stockholm, Sweden
68 61 7,8 880 Turbway 68
Tel.: +47 51 990 000 100 90 9,9 883 Turbway100
Fax: +47 51 990 050 150
www.statoil.com
220
320

ISO Dynamische Viskosität Dichte

Produkt
Viskositätsklasse [mPa s] [kg/m³]

Class of Viscosity Dynamic Viscosity Density

Product
ISO [mPa s] [kg/m³]

40 °C 100 °C 15 °C
22
TOTAL Deutschland GmbH 32 28 4,8 876 Cirkan RO 32
Vertriebsdirektion Schmierstoffe 46 41 6,0 881 Cirkan RO 46
Kirchfeldstraße 61
D-40217 Düsseldorf,
68 60 7,8 887 Cirkan RO 68
Tel.: +49(0)211-9057-0 100 89 9,9 891 Cirkan RO 100
Fax: +49(0)211-9057-300 150 130 13 895 Cirkan RO 150
www.total.de
220 190 17 897 Cirkan RO 220
320 280 20 899 Cirkan RO 320

5
 Viscosity-temperature-graph for mineral oils
(with reference to G. Niemann and DIN 51519)

6
Das RENK Werk in Hannover liefert RENK Hanover plant supplies standard
hydrodynamische, mit Schmierstoff and special hydrodynamically lubricated
versorgte Gleitlager in Standard- und slide bearings for almost any
Spezialausführungen für fast alle application.
Anwendungsbereiche. Gleitlager für Slide bearings for rolling mill drives with
Walzgerüstantriebe mit geschweißten welded housings to absorb maximum
Gehäusen zur Aufnahme extremer loads, for motors, generators and
Lasten, für Elektromotoren, pumps in horizontal and vertical
Generatoren und Pumpen in construction, for fans, water turbines
horizontaler und vertikaler Bauweise, für and conveyors.
Gebläse, Wasserturbinen und
Förderanlagen. For the marine market, the Hanover
plant also offers an extensive range of
Für maritime Anwendungen bietet das standard bearing series, such as thrust
Werk Hannover ebenfalls umfangreiche bearings to take the propeller thrust as
Standardbaureihen, darunter well as for the support of the shaft lines.
Drucklager zur Aufnahme des Customized and application-specific
Propellerschubes und zur Lagerung der maritime solutions, in particular for
Wellenleitungen. Kunden- und naval ships , are also developed and
anwendungsspezifische Lösungen supplied.
werden auch in diesem Bereich,
insbesondere für Marineschiffe,
entwickelt und geliefert.

Änderungen, bedingt durch den technischen Fortschritt, vorbehalten.

We reserve the right to changes made in the interests of technical improvement.

RENK Aktiengesellschaft
Werk Hannover
Weltausstellungsallee 21
D-30539 Hannover
Telefon: +49(0)511-8601-0
Fax: +49(0)511-8601-288
E-Mail: [email protected]
Internet: www.renk.biz

RENK – ein Unternehmen der MAN Gruppe

RENK – a member of the MAN Group

RH-2005 (12.06)

7
 AUTOMATION

GPP
Version 1 – Level Probe in plastic housing
Electric interface through terminal screws in the probe head. Cable feed out through a M16 gland, for protection class IP 65.

• Elektrode lenth available 5 to 4000mm

(please specify with your order)
• 1 - 7 elektrodes
• All parts which may touch the medium are
made from physioligically harmless materials
• For conductive filling level acquisition

Technical data
Mounting method: Thread Probe-head material: PPH
Mounting orientation: any Electrode material: V4A / 1.4571
Media temperature: max. 90°C (optional HAC-C4; Titanium)
Media pressure: max. 10 bar (+60°C) Coating: Polyolifin (optional Kynar)
Sealing ring: NBR 70

Size Electrodes Standard-Model Size Electrodes Standard-Model

1/2“ 1 GPPE - 1VP1 1“ 4 GPPG - 4VP1

1/2“ 2 GPPE - 2VP1 1 1/2“ 2 GPPI - 2VP1
3/4“ 2 GPPF - 2VP1 1 1/2“ 3 GPPI - 3VP1
3/4“ 3 GPPF - 3VP1 1 1/2“ 4 GPPI - 4VP1
1“ 1 GPPG - 1VP1 1 1/2“ 5 GPPI - 5VP1
1“ 2 GPPG - 2VP1 1 1/2“ 6 GPPI - 6VP1
1“ 3 GPPG - 3VP1 1 1/2“ 7 GPPI - 7VP1

Dimensions

Options
Distance fastener Material PPH
Lock-nut Material PPH
Mounting bracket Material V2A / 1.4301
Junction cable with numeric labeled wires

FON +49 (0)40 / 797 150 -0 FAX +49 (0)40 / 797 150 -29 E-Mail [email protected] www. zimmer-automation.com
 Presentation 3
Zelio Control - industrial
measurement and control relays 3

Liquid level control relays RM4 L

Functions
561078

These devices monitor the levels of conductive liquids.

They control the actuation of pumps or valves to regulate levels and are also suitable
for protecting submersible pumps against running empty, or protecting tanks from
"overflow". They can also be used to control dosing of liquids in mixing processes
and to protect heating elements in the event of non immersion.
They have a transparent, hinged flap on their front face to avoid any accidental
alteration of the settings. This flap can be directly sealed.

1 Compatible liquids:
RM4 LG01 2 spring, town, industrial and sea water,
2 metallic salt, acid or base solutions,
2 liquid fertilizers,
2 non concentrated alcohol (< 40 %),
2 liquids in the food-processing industry: milk, beer, coffee, etc.

1
3 2
Non-compatible liquids:
chemically pure water,
2 fuels, liquid gasses (inflammable),
2 oil, concentrated alcohol (> 40 %),
2 ethylene, glycol, paraffin, varnish and paints.

Description
RM4 LG01 RM4 LA32
Width 22.5 mm Width 22.5 mm
561079

1
2 2
R 3 R 3
U U
4

RM4 LA32
1 Fine adjustment of time delay (as % of setting range max. value).
2 Fine adjustment of response sensitivity (as % of setting range max. value).
3 Function selector switch:
- empty or fill .
4 Switch combining:
- selection of the response sensitivity range,
- selection of time delay on energisation or on de-energisation of the
relay.

R Yellow LED: indicates relay state.

U Green LED: indicates that supply to the RM4 is on.

Table showing details for switch 4

Switch position Time delay Sensitivity
500 On-delay High = 500 kΩ range
500 Off-delay High = 500 kΩ range
50 On-delay Medium = 50 kΩ range
50 Off-delay Medium = 50 kΩ range
5 On-delay Low = 5 kΩ range
5 Off-delay Low = 5 kΩ range

References : Characteristics : Dimensions, schemes : Setting-up :

page 3/112 page 3/113 page 3/114 page 3/115

3/110
Presentation (continued) 3
Zelio Control - industrial
measurement and control relays 3

Liquid level control relays RM4 L

Operating principle
The operating principle is based on a change in the resistance measured between immersed
or non-immersed electrodes. Low resistance between electrodes: liquid present. High
resistance between electrodes: no liquid present. The electrodes may be replaced by other
sensors or probes which transmit values representing variations in resistance.
The a.c. measuring voltage which is < 30 V and galvanically insulated from the supply
and contact circuits, ensures safe use and the absence of any electrolysis phenomena.
RM4 relays may be used:
1 For detection of a liquid level, operating with 2 electrodes, one reference electrode and
one high level electrode, or an LA9 RM201 probe. Example: prevention of tank overflow.
1 For regulating a liquid level between a minimum and a maximum level, operating
with 3 electrodes, one reference electrode, one low level electrode and one high level
electrode, or two LA9 RM201 probes.
Example: water tower.
The state of the output relay can be configured:
1 Empty function : the output relay is energised when high level electrode B2 is
immersed and is de-energised when low level electrode B3 is "dry" (1).
1 Fill function : the output relay is energised when the low level electrode is "dry"
3
and is de-energised when high level electrode is immersed (1).
On model RM4 LA32 a time delay can be set on energisation or de-energisation of
the output relay in order to raise the maximum level function or to lower the
minimum level function .
This function also makes it possible to avoid pulsing of the output relay (wave effect)
when operating with 2 electrodes .
Function diagrams
2 Empty function
26Maximum level detection (2 electrodes or 1 probe LA9 RM201)
Type Function Time delay B1 B2 B1 B2 B1 B2
RM4- switch 3 switch 4

U supply
A1/A2
15/18
LG01 Ð 15/16
t t
15/18 25/28
LA32 15/16 25/26
15/18 25/28
LA32 15/16 25/26

26Regulation between a maximum and a minimum level (3 electrodes or 2 probes LA9 RM201)
Type Function Time delay
RM4- switch 3 switch 4 B1 B3 B2 B1 B3 B2 B1 B3 B2 B1 B3 B2

U supply
A1/A2
15/18
LG01 Ð 15/16
t t
15/18 25/28
LA32 15/16 25/26
15/18 25/28
LA32 15/16 25/26

2 Full function
26Maximum level detection (2 electrodes or 1 probe LA9 RM201)
Type Function Time delay B1 B2 B1 B2 B1 B2
RM4- switch 3 switch 4

U supply
A1/A2
15/18
LG01 Ð 15/16
t t
15/18 25/28
LA32 15/16 25/26
15/18 25/28
LA32 15/16 25/26

26Regulation between a maximum and a minimum level (3 electrodes or 2 probes LA9 RM201)
Type Function Time delay B1 B3 B2 B1 B3 B2 B1 B3 B2 B1 B3 B2
RM4- switch 3 switch 4

U supply
A1/A2
LG01 Ð 15/18
15/16
t t
LA32 15/18 25/28
15/16 25/26

LA32 15/18 25/28

15/16 25/26

B1 : reference electrode B2 : high level electrode B3 : low level electrode

(1) When operating with 2 electrodes, the high level electrode performs both high and low level functions.

References : Characteristics : Dimensions, schemes : Setting-up :

page 3/112 page 3/113 page 3/114 page 3/115

3/111
 References 3
Zelio Control - industrial
measurement and control relays 3

Liquid level control relays RM4 L

Liquid level control relays

Time delay Sensitivity Width Output Basic reference, to be Weight
scale relay completed by adding
561087

the voltage code (1)

kΩ mm kg
Without 5…100 22.5 1 C/O RM4 LG012 0.165

RM4 LG01

3 Adjustable 0.25 ...5 22.5 2 C/O RM4 LA3222 0.165

0.1...10 s 2.5 ...50
561088

25 ...500

RM4 LA32

Level control probe for liquid

Type of installation Maximum operating Reference Weight
561089

temperature
°C kg
Suspended by cable 100 LA9 RM201 0.100

LA9 RM201
(1) Standard supply voltages
RM4 LG01 Volts 24 110...130 220...240 380...415
1 50/60 Hz B F M Q
RM4 LA32 Volts 24...240 24 110...130 220...240 380...415
1 50/60 Hz MW B F M Q
2 MW – – – –

Presentation : Characteristics : Dimensions, schemes : Setting-up :

pages 3/110 and 3/111 page 3/113 page 3/114 page 3/115

3/112
Characteristics 3
Zelio Control - industrial
measurement and control relays 3

Liquid level control relays RM4 L

Power supply circuit characteristics

Relay type RM4 LG01 RM4 LA32
Rated supply voltage (Un) 1 50/60 Hz V 24 110...130 220...240 380...415 24...240 24 110...130 220...240 380...415

2 V – – – – 24...240 – – – –

Average consumption 1 VA 1.9 2.6 2.4 2.9 2.7 3.1 2.7 2.6 3.4
at Un

2 W – – – – 2.4 – – – –

Output relay and operating characteristics

Number of C/O contacts 1 2

Output relay state Can be configured by switch: empty / fill

3
Electrode circuit characteristics (1)
Sensitivity scale kΩ 5…100 (adjustable) 0.25…5 2.5…50 25…500

Maximum a.c. electrode voltage V 24 24

(peak to peak)

Maximum current in the electrodes mA 1

Maximum cable capacity nF 10 200 25 4

Maximum cable length m 100 1000 100 20

(1) The electrodes may also be incorporated in the probes. The probes are normally designed for fixing to a tank by means of a bracket with a seal (closed tanks)
or suspended by their own electrical connecting cable (boreholes, etc.). See page 3/115 “Setting-up” Probe LA9-RM201.

Presentation : References : Dimensions, schemes : Setting-up :

pages 3/110 and 3/111 page 3/112 page 3/114 page 3/115

3/113
 Dimensions, Zelio Control - industrial
schemes 3
measurement and control relays 3

Liquid level control relays RM4 L

Dimensions
RM4 LG01, LA32
Rail mounting Screw fixing

6
78

78
80 22,5 89,5

6
82
Ø4
3

Probe LA9 RM201

16

150

Connection schemes
RM4 LG01 RM4 LA32

A1 15 A1 15 25
B1 B2 B3 B1 B2 B3
B1
B2
B3
B1
B2
B3

15

25
15

16
18
26
28
16
18

A1

A2
A1

A2

28 26
18 16 A2 18 16 A2

A1-A2 Supply voltage Electrodes and level controlled

B1, B2, B3 Electrodes
(see table opposite)
B1 Reference or tank earth electrode
st
15-18 1 C/O contact
15-16 of the output relay B2 High level
nd
25-28 2 C/O contact
25-26 of the output relay B3 Low level

Presentation : References : Characteristics : Setting-up :

pages 3/110 and 3/111 page 3/112 page 3/113 page 3/115

3/114
Setting-up 3
Zelio Control - industrial
measurement and control relays 3

Liquide level control relays RM4 L

Setting-up
1 Select the empty /fill function according to the sequence to be performed.
1 If necessary, set potentiometer 1 to minimum (time delay).
1 Set potentiometer 2 to minimum; on RM4-LA, select the lowest sensitivity range
using potentiometer 4 (5 or 5 ).
1 With all the electrodes immersed, turn the sensitivity potentiometer towards
maximum until the relay is energised ( function) or de-energised ( function),
then exceed the threshold by about 10 % to compensate for variation in the supply
voltage.
If the relay is not able to energise, a higher sensitivity scale must be used (selector 4
on RM4 LA32) or relay RM4 LG must be replaced by an RM4 LA32 relay and the
adjustment procedure must be started again.
1 Then check that the relay de-energises ( function) or energises ( function) as
soon as electrodes B3 and B2 are out of the liquid. If the relay does not de-energise,
select a lower sensitivity scale.
1 The electrode connection point must be
protected against corrosion by sticking or sealing.
In areas where thunderstorms are likely to occur,
3
1 measures must also be taken to protect the
2 2 electrode lines.
R 3 R 3 Note: the high level can be raised by means of the
U U
4 adjustable time delay from 0.1 to 10 seconds with
function .
The low level can be lowered by means of this
same time delay with function .
RM4 LG01 RM4 LA32

Probe LA9 RM201

This probe is of the "suspension" type. It is coaxial, i.e. in addition to the normal
(central) electrode, the stainless steel skirt can also act as earth (reference
electrode), which means that there is no need to install a separate reference probe.
In this way, for controlling one level, only one probe is required instead of 2; for
controlling 2 levels, only 2 probes are required instead of 3.
2-conductor cable in
The connecting cable must be of the
cylindrical sheath "2-conductor" type, with common cylindrical PVC
(max Ø 6.3 mm) sheath, having a maximum diameter of 6.3 mm.
The skirt also acts as a "calming chamber", so
Level electrode avoiding inaccuracy due to an agitated surface of
the liquid (waves).
Maximum operating temperature: 100 °C.
Reference electrode Probe LA9 RM201 can also be fixed on various
(skirt)
containers (cisterns, tanks, ...) by means of a
bracket or other suitable fixing device.

LA9 RM201

Connection examples

2 Control by electrodes

A1 B1 B2 B3 High level
B1
B2
B3
Supply voltage

Low level

A2

2 Control by probes
RM4 LG01
B2 B2
B3 B1
B1

2 levels 1 level

Presentation : References : Characteristics : Dimensions, schemes :

pages 3/110 and 3/111 page 3/112 page 3/113 page 3/114

3/115
 Data Sheet 500.D.001.10

Current Transformers

ASK 421.4
ASK 31.3
ASK 41.4
ASK 51.4
ASK 561.4
ASK 81.4
ASK 101.4
ASK 123.3
ASK 127.6
WSK 30
WSK 40
 Window Type Current Transformers
Application
Model Primary Current Width Busbar Aperture
Current transformers convert higher AC currents to standardized sec- Ratings of C.T. Cross - Sections Ø
ondary currents of 1 A or 5 A at definite accuracy classes making them
accessible for measuring duties. ASK 421.4 40 – 500 A 71 mm 20 mm x 10 mm 20 mm
They shall protect the meters and connected equipment from inadmissi- ASK 31.3 50 – 750 A 61 mm 30 mm x 10 mm 26 mm
ble high voltages. In addition they entirely isolate the measuring circuits 2x 20 mm x 10 mm
from the system protecting the meters from overcurrent and destruction. ASK 41.4 50 – 1000 A 71 mm 40 mm x 10 mm 32 mm
Current transformers are available as window types or wound primary 2x 30 mm x 5 mm
types for cable or busbar primaries: ' ASK 51.4 100 – 1250 A 86 mm 50 mm x 12 mm 44 mm
2x 40 mm x 10 mm
D Window type C.T’s (ASK) are mounted on busbars and are suitable
for primary currents from 40 A to 6000 A. ASK 561.4 200 – 1250 A 86 mm 40 mm x 30 mm 44 mm
60 mm x 10 mm
D Wound primary C.T’s (WSK) have a primary winding for lower primary 2x 50 mm x 10 mm
currents from 1 A to 30 A.
ASK 81.4 400 – 2000 A 120 mm 80 mm x 10 mm 55 mm
Window type C.T’s can be used as an inexpensive option where lower 60 mm x 30 mm
currents are involved. The primary conductor will then be passed 2x 60 mm x 10 mm
through the current transformer several times; the primary current being
measured will be reduced accordingly. ASK 101.4 500 – 2500 A 130 mm 100 mm x 10 mm 70 mm
2x 80 mm x 10 mm
All C.T’s comply with VDE 0414 - 44 - 1, DIN 42 600 - 2 and DIN EN 60715
as well as VBG 4. ASK 123.3 750 – 3000 A 172 mm 123 mm x 30 mm 100 mm
3x 100 mm x 10 mm
ASK 127.6 1000 – 6000 A 205 mm 120 mm x 70 mm 70 mm
Functional Principle Standard types are available in accuracy classes 0.5 and 1.
Wound Primary Current Transformers
C.T’s are transformers of lower output. A current–carrying conductor
induces a current in the C.T’s secondary winding. This current can be Model Primary Current Width of C.T. Terminals
measured by a meter connected in parallel. Ratings
The C.T’s ratio is chosen that way to make a secondary current of 1 A or 5
A flow from a defined rated primary current. WSK 30 1 – 20 A 61 mm M5
WSK 40 1 – 30 A 71 mm M5

General Technical Data

Primary Ratings
case details high impact moulded case,
ultrasonically welded Rated Primary Current IN
material of case polycarbonate, flame retardant, 1; 2.5; 5; 10; 15; 20; 25; 30; 40; 50; 60; 75; 80;
self–extinguishing 100 A and any decimal multiple of these values
terminals secondary terminals nickel–plated, as well as the intermediate values 1200; 1250;
with plus/minus combination screws M5x10, 1600 and 1800 A up to 6000 A '
nickel–plated, integrated cover continuous thermal current
mounting push–in fixing feet, ' ID = 1.0 . IN
busbar clamps on window type C.T’s thermal short time current (1 s max.)
insulation material E Ith = 60 . IN
class overcurrent limiting FS 5 up to 1500 A rated primary current
operating voltage ≤0.72 kV factor FS 10 1600 A rated primary current
dielectric test 3 kV rated frequency 50 Hz '
frequency range 50 ... 60 Hz '

Secondary Ratings
Rated Secondary 1 A or 5 A
Current
Rated output 1; 1.25; 1.5; 2.5; 3.75; 5; 7.5; 10; 15; 30
or 45 VA
To keep the limits of accuracy class, the rated output VA shall be chosen
not substantially higher than the actual power demand of the equipment
being connected including the leads.

' also refer to ”Options”

 Data Sheet 500.D.001.10

Current Transformers

Accuracy at Reference Conditions Accessory

accuracy classes 0.5 or 1 '
Primary Busbars
reference conditions
Nickel - plated solid copper busbars (E - CU hard - drawn, drawn accord-
ambient temperature 23°C±1K ing to DIN 46433) in dimensions from 20 mm x 10 mm to 120 mm x 70 mm
primary current 1.0 ... 1.2 IN on request
frequency 50 Hz Note
wave form sinusoidal, distortion factor<5% The aperture of window type C.T’s are not binding for dimensioning the
Limits of error current (ratio) error phase displacement omnibusbar in the switchgear.
in % at in min at The cross - section of the omnibusbar may be smaller over short dis-
1.0 IN 0.2 IN 0.05 IN 1.0 IN 0.2 IN 0.05 IN tances in case a sufficient heat dissipation is reliably provided.
accuracy class 1.2 IN 1.2 IN

0.5
1
0.50
1.00
0.75
1.50
1.50
3.00
30
60
45
90
90
180
Connections
3 3.00 120

Environmental
climatic suitability ' acc. to VDE 0414 - 44 - 1 k l
ambient –5 ... +40°C for indoor use
L1
temperature range K L
in 24–hour average 35°C
relative humidity 70% for indoor use N (L2)

Rules and Standards Dimensions

DIN 42 600 - 2 Metering transformers for use on 50 Hz on request
DIN EN 60 715 Dimensions of low voltage switching devices:
standardized DIN rails for mechanical fixation
of electrical devices in switchgears
DIN EN 60044 - 1 Metering transformers –
VDE 0414 - 44 - 1 Part 1: Current Transformers
VBG 4 Electrical installations and working stock

Options
C.T. type summation, saturation, protective C.T’s,
tube type C.T’s,
special C.T’s suitable for H.R.C. fuse carriers,
or secondary switchable C.T’s
accuracy calibratable or calibrated C.T’s,
with accuracy classes 0.2; 0.5 and 0.5s
on request
mounting mounting adaptor suitable for 35 mm rail
for ASK 31.3, ASK 41.4, WSK 30, WSK 40
rated primary current deviating from standard ratings on request
rated frequency 162/3 Hz up to 400 Hz on request
performance limited use in the tropics or
tropical proof cast–resin insulation
resp. extreme mechanical load
(vibration resistance) on request
Ordering Information
Type
ASK window type C.T’s up to 6000 A
Dimensions busbar cross–sections
421.4 20 mm x 10 mm
31.3 30 mm x 10 mm 2x 20 mm x 10 mm
41.4 40 mm x 10 mm 2x 30 mm x 5 mm
51.4 50 mm x 12 mm 2x 40 mm x 10 mm
561.4 60 mm x 10 mm 2x 50 mm x 10 mm
40 mm x 30 mm
81.4 80 mm x 10 mm 2x 60 mm x 10 mm
60 mm x 30 mm
101.4 100 mm x 10 mm 2x 80 mm x 10 mm
123.3 123 mm x 30 mm 3x 100 mm x 10 mm
127.6 120 mm x 70 mm
Type
WSK 30 wound primary C.T’s up to 20 A
WSK 40 wound primary C.T’s up to 30 A
rated primary 1; 2.5; 5; 10; 15; 20; 25; 30; 40; 50; 60; 75; 80;
current 100 A and any decimal multiple of these values
as well as the intermediate values 1200; 1250;
1600 and 1800 A up to 6000 A
deviating from standard ratings ***)
rated secondary 1A
current 5 A *)
output 1; 1.25; 1.5; 2.5; 3.75; 5; 7,5; 10; 15; 30
or 45 VA
accuracy class 0.5
class 1 *)
frequency 50 Hz *)
162/3 Hz ***)
400 Hz ***)
mounting push–in fixing feet or busbar clamps *)
mounting adaptor for DIN rail (35 mm)
on ASK 31.3, ASK 41.4, WSK 30, WSK 40
performance standard performance *)
limited use in the tropics ***)
cast–resin insulation ***)
special C.T’s summation–, saturation–, protective C.T’s
or tube type C.T’s,
special types for H.R.C. fuse carriers,
secondary switchable C.T’s,
calibratable or calibrated C.T’s ***)
*) standard
**) Please clearly add the desired specifications.
***) on request

Ordering Example
window type current transformer ASK 41.4
rated ratio 500/5 A,
(rated primary current 500 A, rated secondary current 5 A,)
output 10 VA, accuracy class 0.5, frequency 50 Hz

– specifications subject to change without notice; date of issue 11/12 –

Weigel Meßgeräte GmbH
Postfach 720 154 S 90241 Nürnberg S Phone: 0911 / 4 23 47- 0
Erlenstraße 14 S 90441 Nürnberg S Fax: 0911 / 4 23 47- 39
Sales: Phone: 0911 / 4 23 47- 94
Internet: http://www.weigel–messgeraete.de
e–mail: vertrieb@weigel–messgeraete.de
s Siemens Electric Machines s.r.o.

TIGHTENING
TORQUES FOR METRIC
BOLTS

Documentation – Torques in 1.2 page 1/3

P 2-035 (02/02/10)CZ
s
Torques for bolted connections
Siemens Electric Machines s.r.o.

The following table (Tab 1) prescribes the torque figures for bolt connections with strength grade 5.6,
8.8, unless determined otherwise by documentation. Connections are divided into three grades
according to the type of material which they connect.
- Grade A
- Grade B
- Grade C
To ensure an even initial tension created by tightening torque, the threads must be clean (dirt and
remnants of oil must be removed)

Exception to torque figures

Torque figures hereby prescribed do not apply in cases where different torque figures are prescribed by
technical documentation. In case the torque is prescribed by the documentation, a torque spanner must
be used for tightening.
If rubber or another sealing is a part of the connection, the torque figures do not apply either.
In such case, you can roughly adhere to the values of torque figures for grade C (In case of connecting
the cooler housing and the frame by means of elastic resilient pads such as Sylomer or Sylodyn), the
determining factor is the degree of deformation of the elastic resilient pad. The tightening rate should
be 1/10 of the original size, unless otherwise prescribed by technical documentation.

Warning
The given values apply for cases where the movements of a bolt (nut) are not obstructed by other
parasitic forces such as twisting of assembled parts, dirt in threat, threat deformation, non-alignment,
etc.
If the assembly of bolted connections before the actual tightening by torque is hard and it is necessary
to apply force which exceeds 20% of the torque prescribed by the table, it is necessary to remedy the
matter.

Tolerance
Tolerance for tightening by a prescribed torque is – 10%, + 10%.

Grade A (Table1)
Torque figures for bolts for fixed bolt connections of steel and cast-iron parts.
This includes the following parts:
· shield
· bearing assembly unit
· agitator
· cooler (does not apply for connecting the cooler housing and the frame by means of elastic
resilient pad)
· steel covers
· cable end connector
· connection of sleeve bearing to shield
· connection of exciter to shield
· steel and cast iron spacers of rotor winding
· ventilator fans (agitator to hub, balance weight on ventilator fans)
· connections of bus-bars (copper), connection of cables from winding to bus-bars
· fixing of tools and jigs

Documentation – Torques in 1.2 page 2/3

P 2-035 (02/02/10)CZ
s
Grade B (Table1)
Siemens Electric Machines s.r.o.

Torque figures for bolts connecting elements with low strength limit such as aluminium, copper, brass.
This includes the following parts:
· aluminium spacers of rotor winding,
· fibre-glass covers, diode carriers, fibre-glass bus-bar supports
· connection of cables to insulators

Grade C (Table1)
Torque figures for bolts for connecting parts with a very low strength limit.
This includes the following parts:
· insulators,
· plastic and ceramic parts
· rectifiers
· connecting of plastic or ceramic terminal box
Table1
Torques [Nm ] 1)
of strength grade 5.6, 8.8
Threat-nominal Grade A Grade B Grade C
diameter
M4 3 1,3 1,2
M5 5 2,6 2,5
M6 8 4,5 4
M8 20 10 8
M10 40 20 13
M12 70 34 20
M14 110 54
M16 170 83 40
M18 240 115
M20 340 160 110
M22 480 220
M24 600 280
M27 890 420
M30 1200 560
M33 1600
M36 2100 990
M42 2700
M45 3400
1)
Permitted tolerance ± 10%

Torques of chosen machine parts:

Diode torque (D170U25C, D170S25C) ..................... 20 Nm
Terminal box in the main cable box: M10 40 Nm
(Binders – strength grade 8.8) M12 70 Nm
M16 155 Nm
Torques for other cable connections can be found in standard SN 20512.
Please contact Siemens Electric Machines s.r.o. Drásov.

Documentation – Torques in 1.2 page 3/3

P 2-035 (02/02/10)CZ