S E R I E S

BZK
Synchronous Generator s

INDAR ELECTRIC MACHINES

INDAR,
EXPERIENCE AND COOPERATION
INDAR Electrical Machines develops and manufactures
electrical rotating machines to respond to customer needs.

Its experience is shown in the thousands of INDAR

generators in operation all over the world.

Cooperation with the customer is part of the company's

philosophy, through special personal attention as the basis
for the relationship and with a clear common objective: to
develop products and services that adapt to the characte-
ristics of each project.

INDAR has modern facilities equipped with the latest

technology in its different sections; sheet metal die-cutting,
machining, coiling, assembly and testing.
INDAR
Electrical Machines, INDAR is present in several continents through agencies
and after-sales service centres, to guarantee a comprehen-
now part
sive service for its generators: technical assistance, main-
of the tenance, repairs and replacement parts.
INGETEAM Group,
has manufactured,
designed,
and supplied
electrical CONSULTANCY
rotating
machines SUPPLY
for over 65 years.
MAINTENANCE

TECHNICAL ASSISTANCE

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 INDAR E L E C T R I C M A C H I N E S

S E R I E S

BZK

SYNCHRONOUS GENERATORS - BZK SERIES

The development of the BZK series has been based on the knowledge that INDAR has accumulated for decades in
the manufacture of synchronous machines, combined with the use of advanced design tools that its R&D department uses.

Technological innovation is a basic element in the company's development and has become an essential factor in
keeping the company competitive in a demanding market.

Synchronous brushless
generators,
4,111 kVA - 1,000 r.p.m.,
6,300 V,
for a gas
engine for Caterpillar.

MODULAR CONSTRUCTION

The BZK series makes up a three-phase synchro- The construction of the BZK is divided into:
nous generator family designed for horizontal forms of > Casing: The stator core is welded onto the outer
construction. The equipment is designed to comply with ferrule in a cylindrical manner, thus creating the main
different shaft centre heights and anchoring options. It can structure of the generator.
adapt to requirements on the basis of the drive through a
> Shields: Made of mechanically welded rolled steel,
modular design.
both for applications with bearings and those designed
to bear radial and axial loads.

Sizes of the casings

There are 5 casing sizes available:

> 500 > 560 > 630 > 710 > 900

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 Synchronous Gener ator s

CONSTRUCTIVE DESIGNS

Knowledge of the physical phenomena that occur in synchronous machines, together with the latest software to
calculate finite elements, have meant that the electro-magnetic design has been optimised, with excellent performance.

The main characteristics of the BZK series are:

Power (kVA) 1,250 - 15,000

No. of Poles 4 - 10

Voltage (V) 690 - 13,800

Frequency (Hz) 50 - 60

Shaft height (mm) 500 - 900

Insulation F (H if required)

Heating class F

Ambient temperature 40º C

Standards CEI, NEMA, VDE, ANSI

Vibration requirements IEC 34-14 or ISO 10816

Other standards Bureau Veritas, Lloyd´s Register, Det Norske Veritas

Overloads borne without

damage occurring 110% for 1 hour in a 6-hour period
125% for 15 minutes in a 6-hour period
150% for 2 minutes in a 6-hour period

16,000
POWER RANGE
14,000
OF BZK GENERATORS
12,000
Power (kVA)

10,000

8,000

6,000

4,000

2,000
0

No. of Poles 4 6 8 10

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S E R I E S

BZK

S O L U T I O N S F O R E AC H A P P L I C AT I O N

The modular structure of the series means that the The characteristics of the main drive or motor are also
generator can be adapted to a wide range of applica- taken into account when configuring the generator, in
tions based on power, speed or voltage to respond to terms of the level of cooling and protection required
market needs. (adverse environments, high humidity, heat, etc.).

BZK generators provide an energy generation solution for a number of sectors:

> Cogeneration: Gas or steam turbines, diesel or gas engines.

> Shipbuilding sector: Main and auxiliary generation.

BZK 710 (main generation) 6,750 KVA, 1,000 r.p.m., 690 V,

for a dredger of the Belgian ship-owner Jan De Nul.

INDAR generators comply

with current international legislation
on the manufacture of electrical rotating
machines: IEC, CEI, NEMA, etc.

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 Synchronous Gener ator s

R & D AT YO U R S E RV I C E

The team is made up by highly qualified professio-

nals with considerable experience in design and manu-
facture.

This, together with the application of modern simu-

lation programs for finite mechanical elements and elec-
tromagnetic flows, means that we can provide solutions
based on in-house technology to deal with customer
requirements.

Electrical and mechanical optimisation studies have been made using a number of finite element
simulation programs:

> Electrical optimisation:

Our knowledge of the physical phenomena that
occur in synchronous machines, together with the
latest software to calculate finite elements, has allo-
wed us to optimise the electro-magnetic design of
our machines and thus obtain higher performance.

0 / 0.125
0.125 / 0.25
0.25 / 0.375
0.375 / 0.5
0.5 / 0.625
0.625 / 0.75
0.75 / 0.875
0.875 / 1
1 / 1.125
1.125 / 1.25
1.25 / 1.375
1.375 / 1.5
1.5 / 1.625
1.625 / 1.75
1.75 / 1.875
1.875 / 2

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S E R I E S

BZK

COOLING AND PROTECTION

INDAR offers a range of solutions, depending on the demands of the application or customer requirements, ranging
from open air-cooled machines to closed machines with air/water cooling systems.

OPEN MACHINES NOMENCLATURE OF PROTECTION CLASSES

There are two configuration options: IP: first number

Those that take and expel the cooling air from Indicates the level of protection against acci-
machine room IC 01. They can be used in pla- dental contact between live parts and the pe-
ces where the air is relatively clean. netration of solid bodies.

Those that take ambient air from the machine 2. Drives protected against objects larger
room and expel the hot air through a duct out- than 12 mm.
side of room IC 21.
4. Drives protected against objects larger
than 1 mm.

5. Drives protected against penetration by dust.

CLOSED MACHINES

In cases in which the air is not sufficiently IC-01 second number

clean or not suitable for ventilation, the solution
consists of completely closed generators with Degree of protection referring to the tightness
two types of cooling system: of the drive against penetration by liquids.
Those that take and discharge air outside 3. Drive protected against drops of liquid at an
through an IC 31 duct. angle of 60º (rain).

Machines with IC-81W81W cooling have a closed 4. Drive protected against splashes in any direction.
air circuit. The air that is ventilated by the machi-
ne goes through the coolants located on the 5. Drive protected against water jets.
outside of the generator. The water that runs
through the cooling units extracts the heat ge- 6. Drive protected against high seas.
nerated in the machine.

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 Synchronous Gener ator s

S TATO R

The stator package consists of low-loss thin sheets of MAGNETIC CORE

magnetic silicon steel, which are die-cut and coated on
The magnetic core is held in place by tie bolts that
both surfaces with insulating material to reduce losses
make up a pressure box on the outside, with the help of
from stray currents.
some pressure plates with pins located on either side of
the core.
The spaces that make up the radial air ducts in the
core of the stator are distributed to ensure efficient cooling.
This system guarantees high mechanical rigidity of
the magnetic core through an excellent compacting of the
The shields attached to the central part are studied
steel sheets.
by modern calculation methods such as Finite Element
Modelisation (FEM) to bear the most demanding electro-
magnetic stresses.

The bearings are located in the shields. They are de-

signed to handle a range of cooling solution in terms of
air inputs and outputs.

The cooling of the magnetic core and coils is divided

into a number of basic 'packages' with radial ventilation
channels made up of sheet metal with spacers attached.

The spacer core is selected to achieve uniform distri-

bution of the pressure applied during the formation of the
core, thus guaranteeing low hydraulic resistance to obtain
the necessary air flow for cooling.

Once the core has been formed a non-destructive test

is carried out at low induction, with the aim of detecting
short circuits between the plates.

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S E R I E S

BZK

COILS

FORMATION OF COILS
Each coil is made up of individually insulated copper
platens. Once the coil is formed a number of layers of Mica
tape are applied to ensure reliable insulation.

After insulation, protection is applied to the rated voltage

of the machine.

The objective is to avoid differences of potential between

the surface of the insulation and the iron of the magnetic
package in the active part of the coil, and also discharges
in the area around the head of the coil.

The insulation of the generator is guaranteed to the

Class F Standard used by INDAR, but it depends on the
working environment or the specific needs of the customer.
WINDING
Class H insulation can also be used.
An element that guarantees the performance of INDAR
generators is the high level of insulation of its components.

The stator winding is three-phase and is insulated by

the VPI System. This insulating system has excellent
dielectric, thermal and mechanical characteristics.

Its reliability is backed up by hundreds of machines that

have been manufactured in recent years using this system,
not only under normal operating conditions but also under
transient conditions.

Stator winding.
Individually insulated copper platens.

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 Synchronous Gener ator s

P RO C E S S O F I M P R E G N AT I O N

INDAR generators undergo the most reliable processes to produce machines that will operate for decades, even
under the most adverse conditions.

As a result of this process of impregnation, the magnetic package, the coils, the wedges, the fastenings and the
supports of the head make up a compact unit that is capable of supporting all the mechanical and electrical stre-
sses the machine can be subjected to, even transient regimes as a result of discharges, disconnection operations, etc.

The windings are characterised by:

> High mechanical resistance in all parts of the winding, > The insulating materials are not affected by humidity;

due to the fact that the coils, the magnetic package if water does get into a particular area the machine

and the supports have all been impregnated at the can started up again after drying the wet surface.

same time. > It is not sensitive to oil and other contaminants, and

> Uniform dielectric strength throughout the circuit. the low roughness of its surface avoids the accu-
mulated of dust.
> Total absence of gaps in the insulation. This gua-
rantees excellent thermal conductivity and good > High resistance to the effects of radioactive radiation.

dielectric properties. This means the machines can be installed in areas

of high radiation in nuclear plants.
> High thermal capacity. All the insulating materials
comply with Class F, and may therefore be conti- > The insulation system is inflammable and self-

nuously subjected to temperatures of up to 155º C. extinguishing.

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S E R I E S

BZK

ROTOR

The design of the rotor is a key factor in the mechanical and electrical performance of the generator. The rotor of BZK
generators is the best example of the work done by the company's R&D Department in the ongoing optimization of the design
of the generators.

> For 4 poles rotors: the rotor package consists > For 6, 8 and 10 poles rotors: the rotor con-
of thin low-loss magnetic silicon steel sheets. They are die- sists of rolled steel plates that are pressed together and
cut and coated on both surfaces with insulating material to welded to two discs to make up a compact core that is
reduce losses from stray currents. These sheets are pressed then linked to the shaft.
against each other, leaving radial channels that reinforce
the cooling of the rotor winding and thus ensuring efficient
cooling of the generator.

The copper-insulated coils are inserted into the grooves

and are insulated from the rotor sheet metal. The coils are
held in place in the grooves by fibreglass wedges.

The assembled rotors undergo tests in the tunnel to The poles manufactured from rolled steel create a
ensure their correct operation. The tests include dynamic compact unit consisting of the earth and the polar coil.
balancing and overspeed tests to check the structural They are then subjected to an insulation process that gives
integrity of the components after the tests. them great rigidity and avoids air inclusions in the spirals.

The rotor has a dampening coil that reduces the effect of

unbalanced loads, improves the stability of the generators and
dampens the oscillations caused by sudden load changes.

The shafts used in the construction of the generators

are manufactured with top-quality steel (forged or rolled) and
then subjected to specific tests to check the homogeneity The field winding consists of insulated copper. The
of the material. They are machined along their entire length current to this winding is injected through an exciter/rectifier
and are polished on the surfaces where the bearings slide. bridge or a set of rings.

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 Synchronous Gener ator s

BEARINGS

INDAR offers two solutions, depending on the type of application: ball bearings or slide bearings.

BALL BEARINGS SLIDE BEARINGS

Under normal operating conditions they have a forecast These have a working life of over 100,000 hours. This
working life of at least 50,000 hours. is the recommended system for high-speed or high-
vibration applications. They are installed under special
manufacturing conditions (rotation speed, load-bearing
capacity) or according to customer requirements.

The lubrication of the bearings can be done in two

ways, depending on operating conditions: self-lubricating
or through an external lubricating mechanism.

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S E R I E S

BZK

CONNECTION BOXES

In the BZK series, the connection box is assembled It is mounted on the stator and provides all the con-
on top of the generator and includes the transformers nections for the connection and protection elements:
required for excitation (T1 and T2). temperature sensors, excitation, current transformer out-
puts, heaters and similar equipment.
It is designed to enable easy connection of the ca-
bles and the installation of the current and voltage trans-
formers for measurement and protection. Cable connec-
tions in the standard series can be either on the right or
the left side.

For high- and medium-voltage machines, the auxilia-

ry connection box is located away from the main connec-
tion box.

The standard The main connection box complies

protection with Standard DIN 42962
of the in terms of distance between terminals,
connection insulators and walls.
box is IP 54.

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 Synchronous Gener ator s

T Y P E O F E X C I TAT I O N

The BZK series has a range of options, depending on the application and the voltage of the machine. Basically, there
are three systems of brushless excitation:

> Powered by ancillary equipment. > Powered by PMG.

The AVR is powered by an external AC source. This The excitation equipment is powered by a Permanent
is the simplest system although it is not always Magnet Generation mounted on the opposite side
possible to apply it. If the power supply to the from the main generator. The PMG supplies the
excitation equipment can be guaranteed it can power required by the AVR, even in cases when it
comply with 3 In (and similar) demands. is necessary to comply with demands such as
maintaining a level of short circuit for a short period.

> Powered by terminals on the generator.

This is a system in which the equipment is powered
by a transformer, whose primary is connected to the
generator output and the secondary to the excitation
equipment. In cases where 3 In is required or gua-
ranteed, a Boost module is installed (with its corres-
ponding transformer).

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S E R I E S

BZK

R E G U L AT I O N

REGULATION SYSTEM
The regulation system is through a reliable micropro-
cessor that can be custom-built. It regulates the output
voltage of the brushless generators by controlling the
current in the excitation of the generator field.

For operations in parallel with the main generator, the

way the power factor control is designed allows a conti-
nuous supply of reactive current. When supplying insulated
networks, a single voltage control is used.

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 Synchronous Gener ator s

GENERAL TESTS

Components and the different parts of the generator are checked and tested throughout the manufacturing process. The
controls include: Quality control, test to ensure insulation, inspection on reception of products, etc.

These ongoing checks during the manufacturing process and the final tests guarantee the total reliability of INDAR
generators.

The routine tests that INDAR applies to its generators are:

> Measurement of the winding insulation.

> Measurement of the insulation resistance.
> Phase sequence and direction of turn.
> Vacuum curve.
> Short circuit curve.
> High voltage test.
> Overspeed test.
> Dielectric strength test.
> Checks on auxiliary components.
> PT 100.
> Heater.
> Regulator.
> Visual checks.

Standard tests that INDAR carries out in accordance

with Standard IEC 34 are:

> No load heating.

Synchronous Machine. > Heating under short circuit.
Test under Load.
> Determination of losses and efficiencies.

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BZK

S TA N DA R D AC C E S S O R I E S I N T H E B Z K R A N G E

PT-100 OPTIONAL
TEMPERATURE SENSORS ACCESSORIES
These are temperature sensors consisting of a platinum INDAR offer the following additional accessories.
filament surrounded by cylinder-shaped ceramic material They can be included in the BZK range to cover any
in a metallic sheath (in the case of bearings) or flat in the requirement.
case of windings.
> Cooling air filter.
All BZK machines have 6
PT-100 (2x3) installed in the > Air/water cooler with water loss sensor.
winding, and 2 PT-100 in ea-
ch slide bearings. If antifric- > PT-100 in hot/cold air.
tion bearings are installed,
there is 1 PT-100 in each of > PT-100 in hot/cold water.

these bearings.
> Extra PT-100 in bearings.

> Thermometers.
HEATING RESISTANCE
Heat resistors keep the air inside the generator at 5ºC > Current transformer for measurement and protection.
above ambient temperature. They are used to avoid
> Voltage transformer for measurement.
oxidation from water condensation during long shutdowns
of the machine, and to maintain the dielectric properties
> Sea transport packing.
of the insulation.

Two single-phase power resistors are installed on both

sides at the bottom of the generator.

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Synchronous Generators

Power 4,111 kVA

Voltage 6,300 V,
Speed 1,000 r.p.m.

Power 4,050 kVA,

Voltage 6,300 V,
Speed 1,500 r.p.m.

Power 6,550 kVA,

Voltage 6,300 V, Speed 1,500 r.p.m.

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BZK

OUR FINAL PRODUCT

Power 3,750 kVA,

Voltage 690 V,
Speed 1,000 r.p.m.

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20200 Beasain - Gipuzkoa (Spain)
Tel. +34 943 028 200
Fax +34 943 028 204
www.indar.net