Siemens JF DIFG

Wind power generator
Type JF
Operating Instructions / Installation Instructions
Edition 05/2013
Answers for industry.

Operating Instructions / Installation Instructions
Document Rev. Release Affected Remarks

Date Pages
BWA-JF-en-01-Rev8 8 1.11.2012 10 Heating with thermostat removed
13,17f,22 description for brush blocker added
13,29 cleaning of slipring cabinet
19 Trip levels for temperature sensors removed
25f lifetime of brush changed / regular maintenance
interval changed / brush operating time
31 text for two-layer brush removed; litz wire laying
added
35 summary table completed / inspection intervals
changed
40 pictures in Appendix A added
BWA-JF-en-01-Rev9 9 01.05.2013 14,23 Permission of work at -15 °C removed
15 Cooling water quality generalized
19 Chapter 4.5 revised
22, 35 First maintenance interval after max. 4000 h
24 Remove waste grease from grease ducts
26 Remaining operating time after wear limit 500 h
27,35 Check of spring carriers
30 Turn shaft manually removed
Subject:
Low voltage asynchronous generators;
with slipring rotor; internally air cooled
Type code of generators; general:

Example: J F W A - 5 0 0 S R - 0 4 A
- -
code:
J: internally air cooled

A: surface or water jacket cooled
F: LV stator, slipring rotor

P: HV stator; slipring rotor
G: LV stator; squirrel cage rotor
Q: LV permanent magnet rotor
X: HV permanent magnet rotor
cooling design:
„W “ = water cooled
„E“ or „R“ = air-air cooled
„S“ = surface cooled
design
frame size (shaft height in mm)
frame length
design
pole number(s) (e.g. „64“= 6+4 pole)
mounting arrangement
(e.g. „A“ = IMB3 acc. IEC60034-7)
BWA-JF-en-01-Rev9 page 2 of 44
Table of contents
Page
1 General Instructions for safety and commissioning ................................................... 4
2 Description ................................................................................................................. 7
3 Transport and Handling ........................................................................................... 11
4 Installation and commissioning ................................................................................ 14
5 Maintenance ............................................................................................................ 23
6 Spare parts .............................................................................................................. 36
7 Environment and health precautions ....................................................................... 37
Appendix A .................................................................................................................... 39
Appendix B .................................................................................................................... 43
This instruction manual is to be used in connection with the specific
product documentation (diagrams, data sheet, spare part list, etc.)
valid for the individual type of generator.
General Instructions for safety and commissioning
1 General Instructions for safety and commissioning
1.1 General
Low voltage machines have dangerous, live and rotating parts, and hot surfaces. All work
for transport, connection, commissioning and maintenance is to be made by qualified,
responsible specialists (EN 50110-1 / VDE 0105-1, IEC 60364 must be observed).
An inadequate proceeding can cause severe damages to persons and property.
1.2 Specified use
These low voltage electrical machines are intended for use in industrial environment. They are
in accordance with the harmonized standards of the series IEC / EN 60034 (VDE 0530).
Their use in hazardous areas is prohibited.
Conditions at the site of application must comply with all data indicated on the nameplate (e.g.
ambient and cooling medium temperature, site altitude above mean sea level, cooling medium
flow rate).
1.3 Directives (relevant for handling the product within the “European Economic Area”)
- Low Voltage Directive 2006/95/EC:

The manufacturer proofs accordance with the directive by “Declaration of Conformity”.
Conformity is proved by the compliance with the standard “EN 60034”.
- Directive „Electromagnetic Compatibility“ 2004/108/EC:

These low voltage electrical machines are intended for use in combination with a frequency inverter as an
“adjustable speed electrical power drive system”. Electromagnetic compatibility can only be considered
for the complete installation by application of the relevant standards (e.g. EN 61800-3). In addition the
assembler of the complete installation has to regard standards specifically valid for the application (e.g.
EN 61400-21) and the utility guidelines and requirements.
Internal electromagnetic compatibility of the different components of the installation between each other
has to be provided by the assembler; e.g. with relevant instructions for erection or cabling.
- Directive 2002/95/EC „on the restriction of the use of certain hazardous substances in electrical
and electronic equipment”:
According to the scope of this directive this product is not covered by this directive. Possibly problematic
substances and handling recommendations: see chapter 7.
For a long time now, we have been committed to developing and producing ecofriendly items of
equipment. This includes avoiding the use of hazardous substances in our products, without this
adversely affecting the benefits that these products have for our customers.
- Directive 2002/96/EC „on waste electrical and electronic equipment (WEEE)”:

According to the scope of this directive this product is not covered by this directive; this product is not
intended to be integrated into a product covered by this directive.
The user is responsible for correct treatment and recovery of the product after life time.
1.4 Transport
(general; details see chapter 3)

The carrier is immediately to be informed on damages found upon delivery; commissioning
must not be admitted, if required.
Screwed-in lifting eyes are to be tightened. They are only suitable for the weight of the
electrical machine; no additional loads are allowed to be attached. If required, sufficiently
dimensioned means of transport (e.g. rope guides) are to be used.
Observe instructions attached on the packing.
If electrical machines are equipped with cylindrical roller bearings they are delivered with transport locking
devices in order to prevent damages caused by vibrations at standstill.
Reuse these transport locking devices for further transports. Provide a transport locking device if the
generator is assembled together with the drive train and transported to the site. Depending on the
components of the drive train (coupling) it might be necessary to provide a customer specific solution
under the responsibility of the customer.
The transport locking devices have to be removed prior to commissioning.
1.5 Storage

For storage of the generator take care of a dry, dust-free and low-vibration ambience, see 3.4.
Before commissioning the insulation resistance has to be measured. If the limit values (see 4.6) are
exceeded the winding must be dried.
Depending on the storage time regard the precautions in chapter 3.4.
1.6 Mounting

Observe instructions for mounting (even ground, exact alignment).
Special guideline for coupling: see 4.2, 4.3.
It has to be avoided that structure-dependent natural frequencies occur within the range of the rotary
frequency and the double mains frequency. Turn rotor manually listen to abnormal frictioning noise.
Couplings are only allowed to be installed or removed with suitable devices and according to the
instructions of the coupling manufacturer.
The balancing mode of the low voltage machine is indicated on the shaft end face or on the nameplate.
The coupling has to be balanced accordingly.
All rotating parts have to be covered with protection against accidental contact.
If required, provide the necessary connections for the cooling medium (air ducts or pipe connections).
Observe the correct direction for the cooling medium flow.
1.7 Electrical connection
Observe data on the nameplate as well as the wiring diagram.

Observe connection of winding according to the nameplate.
Connection is to be made in such a way that a durably safe, electrical connection is maintained; observe
clearances e.g. between cable shoes, provide suitable cable end equipment.
Observe safe earth connection.
Connection of additional devices (e.g. encoder): see the terminal diagram and instructions of the technical
documentation, e.g. concerning earth connection and cable shielding.
The assembler of the complete installation is responsible for the correct wiring (separation of signal
cables and power cables, use of shielded cables where required …).
The instructions of the inverter manufacturer have to be observed, especially regarding electromagnetic
compatibility.
1.8 Operation and maintenance
Operation:
Operation only within the specified range of technical data (environment conditions and operation data)!
In case of any variations compared to usual operation (e.g. higher temperature, noise, vibration) the
cause is to be found. If required, consult the manufacturer.
The safety devices are not allowed to be put out of function even for trial operation.
In case of doubt the machine has to be switched off.
Maintenance:
Observe manufacturer instructions for maintenance (e.g. lubrication, cleaning, maintenance of brushes;
see chapter 5 Maintenance).
1.9 Warranty
Warranty is only applicable if all of these instructions for operation and maintenance are strictly observed.
Prevent failures and thus avoid damages to persons and property:
The person responsible for the installation has to make sure, that
– safety- and operating instructions are available and observed,
– operating conditions and technical data are observed and
– protective equipment is used.
In addition to these instructions the applicable instructions for the inverter have to be observed.
Maintenance work has to be carried out as specified and has to be documented.

Only the specified original spare parts are allowed to be used.
In case of using alternative components the warranty claim becomes invalid.
Description
2 Description
2.1 General
Three phase generators of this type are intended for speed variable operation in the configuration
„Doubly Fed Wound Rotor Induction Machine“: Using additional equipment (switchgear and a frequency
inverter) the generator stator is grid-connected while the rotor is fed with adjustable frequency and
voltage. The admissible range of speed, power and electrical data according to the technical data has to
be provided by superimposed control functions.
The generator is provided with a nameplate for fundamental data according to IEC standard (sinus
operated with brushes shortcircuited) and additional nameplate(s) for technical data when inverter
operated.
2.2 Basic design
Mechanical design:
Dimensions, technical data and mounting type according to DIN EN 60034-7:
see individual dimensional diagram.
Cooling type according to DIN EN 60034-6:

Version with air-to-air heat exchanger; type code e.g. JFE…, JFR…:
cooling type IC 6A1A6 (short form: “IC 616”)
Version with air-to-water heat exchanger; type code e.g. JFW…:
cooling type IC 8A1W7 (short form: “IC 81W”)
Degree of protection (generator housing and slipring compartment might be different):
see “Technical Data”.
Electrical design:
Three phase winding in stator and rotor as a form- wound winding; the rotor winding is connected by a
slipring device.
2.3 Generator housing
The generator frame is made of cast iron or steel; the end shields are made of cast iron or steel.
2.4 Bearings
The generators are equipped with antifriction bearings.

The bearings are grease-lubricated, have regreasing units and automatic grease quantity regulators.
As an option an automatic regreasing unit can be installed, see individual dimension diagram and
technical data. The generator is delivered greased ready for operation.
Description
Both bearings are equipped with an electrical insulation to prevent bearing damages by bearing currents.
In addition a grounding device for the rotor is installed to avoid bearing voltage caused by capacitive
coupling (slipring with grounding brushes on NDE side or both on NDE and DE; depending on individual
design; see dimensional diagram).
Operation without grounding device is not permissible because of the high voltage occurring at the rotor
in this case. Although the bearing insulation is designed to withstand this high voltage, harmful shaft
voltages and capacitive bearing currents could occur and damage the bearings.
The brushes are equipped with monitoring contacts for wear indication.
2.5 Slipring device
The rotor winding is connected to the terminal box via sliprings and carbon brushes.
Sliprings and brushes are protected within the slipring enclosure; the chamber is cooled by means of a
separate air ventilation. The brushes are equipped with monitoring contacts for wear indication.
2.6 Terminal boxes
Design and number of terminal boxes: see dimensional diagram.

As a rule the generator provides a main terminal box (stator connection) and a rotor terminal box as well
as an additional terminal box for monitoring devices and other additional components.
2.7 Cooling
General: Technical data: see dimensional diagram and technical documentation.
2.7.1 Internally cooled with air-to-air heat exchanger (type code e.g. JFEx; JFRx)
The generator is equipped with an air-to-air heat exchanger mounted to the generator frame. The
generated heat dissipation is led to the heat exchanger by the internally closed air circulation. Cooling
medium of the external cooling is air. It is blown through the heat exchanger by forced ventilation.
2.7.2 Internally cooled with air-to-water heat exchanger (type code e.g. JFWx)
The generator is equipped with an air-to-water heat exchanger mounted to the generator frame. The
generated heat dissipation is led to the heat exchanger by the internally closed air circulation. Cooling
medium of the external cooling is water or a water/ antifreeze mixture.
As a standard the coolant circulation and re-cooling is provided by the plant equipment.
Description
2.8 Speed sensor (encoder)
A speed sensor is mounted on NDE of the generator for the inverter control system (data see technical
documentation). Correct electrical coordination with the inverter including design of the wiring (cable
shield) has to be carried out according to the inverter manufacturer. The speed sensor is electrically
isolated from the generator shaft to avoid bearing currents and EMC problems.
2.9 Monitoring devices, additional devices
As a standard the generators are equipped with:

- temperature sensors for stator winding and bearings
- wear indicator for the brushes and
- speed sensor
- anti-condensation heater (“space heater”)
Terminals are provided in terminal boxes or as plug connectors (speed sensor).
Additional devices can be equipped as an option (e.g. surge arresters).
2.10 Operational conditions
Environmental conditions, cooling

Permissible ambient temperature, coolant temperature and altitude above sea level:
see nameplate and technical documentation.
Dielectric stress of rotor winding:

Caused by inverter operation in general the dielectric stress of the winding is increased:
Permissible peak voltage (line to line and line to ground): max. 2.5 kV;
the rise time of the voltage pulses to be more than 1 µs (according dV/dt < 2 kV/ µs)
If necessary the above values have to be realized by means of dV/dt- filters within the inverter.
Operation at zero power („coasting“) operation at low power:

Coasting for a longer period causes excessive brush wear, since the oxide layer is removed
(except a normal period of 1–2 days for commissioning). With the oxide layer already existing from
operation a coasting for a definite period of some days normally is harmless.
(Coasting over a longer period is only admissible if an auxiliary idle current is provided by the inverter in
order to conserve the oxide layer.)
Plant Standstill:
Vibration:
At standstill of the wind power plant the generator must not be subject to higher vibrations than 0.5 mm/s.
In case of higher vibration values at standstill, standstill marks and damages in the antifriction bearings
can occur.
Condensation:
For longer periods of standstill when condensation inside the generator could occur the space heater
has to be activated. The space heater must not be used during operation of the generator.
The recommended trip levels for switching the space heaters on and off can be found in chapter 4.5 Trip
levels for space heaters.
Description
Notes for operation at low temperatures:

The use of a space heater in the slipring unit is recommended, if the machine shall be operated below
0 °C. The minimum total power is 500 W.
With the use of a space heater in the slipring unit, the permitted operation is expanded from an ambient
temperature of -20 °C to -30 °C (standstill/idling mode: -40 °C).
In case of an air-water cooling, please note the water / antifreeze mixture ratio in chapter 4.1.2 Version
with air-to-water heat exchanger.
If the machine is equipped with an automatic lubrication system, please note also the corresponding
documentation.
2.11 Protection
The superimposed control of the plant has to ensure operation only within the admissible range of data.
Measures have to be provided against overshooting the maximal permissible speed of the generator
(see name plate and technical documentation).
Provide a monitoring device for the operation of the forced ventilation or the coolant flow.
The temperature of winding and bearings is continuously to be monitored.
The temperature monitoring has to be regarded immediately; the signal from the brush wear indicators
with a permissible delay time (delay time see chapter 5 Maintenance).
Transport and Handling
3 Transport and Handling
3.1 Transport
(environmental conditions during transport according EN 60721-3-2: see technical documentation)

For handling during transport the stator construction of the generator is equipped with lifting eyes, where
the lifting hooks can be fixed.
Ensure that screwed-in lifting eyes are tightened.
Attach the generator only to these lifting eyes. The lifting eyes must always be used together; see
dimensional diagram.
The generator lifting eyes are only suitable for the generator weight. Additional loads
attached to the generator must never be lifted using these eyes.
Lifting of the generator on other parts (e.g. shaft end) is not permitted, since this might
result in considerable damages.
The lifting eyes of the heat exchanger are exclusively intended for lifting the heat
exchanger alone. Do never use them for lifting the complete generator!
3.2 Check before installation
Check whether the generator has been damaged during transport. If the packing is damaged to such an
extent that generator damage is to be assumed, the packing should only be removed in the presence of a
representative agent of the carrier.
3.3 Bearing lock
Generators with ball bearings usually are shipped and can be transported without a bearing lock.
Generators with cylindrical roller bearings are equipped with a bearing lock in order to avoid damages to
bearings caused by vibrations at standstill; the design can be seen in the dimensional diagram.
Reuse these transport locking devices for further transports. Provide a transport locking device if
the generator is assembled together with the drive train and transported to the site. Depending on
the components of the drive train (coupling) it might be necessary to provide a customer specific
solution under the responsibility of the customer.
The transport locking devices have to be removed prior to commissioning.
3.4 Storage; long-term storage
(environmental conditions during storage according EN 60721-3-1: see technical documentation)

General:
The precautions are valid for:
- storage before mounting the generator
- storage after mounting the generator in the drive train (e.g. in the nacelle before commissioning)
- longer periods of standstill of the plant (e.g. in case of a plant failure)
Observe the ambient temperature limits for storage according to technical data.
Temperature conditions of the ambient air have to ensure that no condensation of water can occur at the
generator.
If this can’t be assured (e.g. in the nacelle in site) the anti condensation heater of the generator has to be
activated.
Take care of a dry and dust-free ambience. Take care of low-vibration location (< 0.2 mm/s) in order to
avoid bearing damages with generator at standstill.
The machines are conserved when delivered from factory: uncoated surfaces (e.g. shaft extension) are
protected with an anti-corrosion coating.
If removed, such a protection has to be attached again for a repeated storage.
To be regarded when cleaning the generator surface (particularly in the area of the bearings):
- Do not use a high-pressure cleaner!
- Do not use a fat dissolving cleaner!
Water cooled version:

To prevent damages from corrosion and frost, remove the water entirely from the cooling circuit.
If the cooling circuit had been filled with additional antifreeze, the antifreeze has to be removed. As the
residues of the antifreeze might cause corrosion problems, the cooler has to be rinsed with pure water.
Ensure that the water circuit is totally empty.
If the generator has been operated with operational speed more than 200 rpm before the intended
storage (e.g. during a test run) the bearings shall be regreased afterwards in order to prevent corrosion.
Regrease each bearing with 4 times of the grease quantity as required for periodical regreasing while
rotating the generator slowly (approx. 2 rpm).
Storage time up to 2 years:

Recommended measures
The machines shall be stored in a dry, dust-free and tempered room. A special packing is not necessary
then. In all other cases the machines have to be packed in a plastic bag with a desiccant (e.g. Branogel)
or in an airproof sealed foil. Use a protective cover against sun and rain.
A desiccant (e.g. Branogel) has to be put into the terminal boxes of the machines.
Lift the brushes from the slipring. Use the brush blocker, which where mounted on delivery to lift the
brushes, see also chapter 4.4. If you don’t have the brush blocker, contact the Service Center.
Turn the shaft every six months slowly (approximately 2 rpm) five turns counter clockwise and five turns
clockwise by hand. Take care that the final position is different from the initial position to prevent standstill
marks.
Regrease both bearings with type and quantity specified on the nameplate every six months.
Change the desiccant every six months.
During commissioning:
Remove the desiccants.
Regrease the bearings with twice the grease quantity and grease type specified on the nameplate.
Remove the brush blocker and reinstall the brushes, see also chapter 4.4.
Take care that the cables of the brushes can move freely so that they don’t get caught.
New sliprings without patina on the track can be cleaned with a clean cloth moistened with a released
cleaning agent.
Detailed instructions for cleaning the slipring cabinet and a list of released cleaning agents can be found
in chapter 5.3.2.
Storage time more than 2 years:

In addition to the above mentioned measures additional instructions have to be regarded how to handle
the generator for the storage time and before commissioning. Please contact the Service Center.
Preventive measures, at least:
Periodically, each 2 years:
Regrease each bearing with 4 times of the grease quantity and grease type as specified on the
nameplate while rotating the shaft slowly (approximately 2 rpm).
Remove the desiccants.
Regrease the bearings with 4 times the grease quantity and grease type specified on the nameplate.
Remove the brush blocker and reinstall the brushes, see also chapter 4.4.
Take care that the cables of the brushes can move freely so that they don’t get caught.
New sliprings without patina on the track can be cleaned with a clean cloth moistened with a released
cleaning agent.
Detailed instructions for cleaning the slipring cabinet and a list of released cleaning agents can be found
in chapter 5.3.2.
Depending on the individual storage time and storage conditions there might be additional measures
necessary which cannot be defined generally.
Installation and commissioning
4 Installation and commissioning
General precautions:
Low voltage machines have dangerous live and rotating parts and hot surfaces. Observe high
acoustic noise level and use protective devices according to the relevant regulations. All work
for transport, connection and commissioning is to be made and documented by qualified,
responsible specialists. An inadequate proceeding can cause severe damages to persons
and property.
4.1 Environmental conditions, cooling
(environmental conditions during operation according EN 60721-3-3: see technical documentation)

General: The slipring compartment is ventilated by a separate air flow (as a rule with a degree of
protection less than the generator; see technical data). No exhalation of silicone-containing sealing
compounds must be admitted to the intake air of the slipring enclosure.
The outlet air is wearing attrition of the brushes. According to the appropriate local regulations the attrition
shall be collected in an air filter before the air is blown into the environment.
Regard that the brush attrition is flammable. Observe the environment and health precautions (chapter 7).
4.1.1 Version with air-to-air heat exchanger
Permissible ambient and cooling air temperature and altitude above sea level:
see nameplate and technical documentation.
The generators are equipped with a fan (or fans) for forced ventilation of the external cooling air. Correct
direction of rotation of the fan(s) has to be observed (see marking plate on generator).
Care must be taken that the cooling air can flow without hindrance into the air inlet openings and freely
pass through the air outlet openings.
For sufficient dimensioning of air ducts observe the air flow rate according to technical documentation.
Observe the increased temperature level of the outlet air flow.
The warm outlet air must not be directly sucked in again. Best solution is to provide the inlet air from
external environment. Suction and outlet openings must be protected from obstructions and coarse dust.
Ensure that the fan(s) can rotate freely before the first starting of the fan(s). Provide
protection if any foreign bodies accumulated during commissioning should be blown
out.
General:
It must be ensured that the generator is only switched on if the ventilation is working. Provide a
monitoring device for the operation of the forced ventilation.
Depending on the individual design a special control of the flow rate depending on the load condition is
provided, e.g. by changing the speed in case of 2-speed fans; see technical documentation.
4.1.2 Version with air-to-water heat exchanger
Permissible coolant temperature, coolant flow rate and ambient temperature: see nameplate and
technical documentation. (In some cases the generator is designed for different cooling conditions
according to different load conditions.)
Connectors for water inlet and outlet are located on the housing of the heat exchanger.
(Dimensions: see dimensional diagram. Observe the correct direction of coolant flow!)
Route and support the water pipes so that the connecting flanges are not exposed to excessive stress or
strain or vibration loads.
Circulation of the cooling water with the correct flow rate and re-cooling has to be provided by the plant
installation.
Observe the maximum permissible system pressure according to technical data.
Notice
Danger of corrosion
If the cooling water quality is unsuitable, the air-to-water heat exchanger may suffer corrosion and fail.
- The chemical composition of the cooling water must comply with the configuration specifications.
- If the cooling water quality deviates from that stated when ordering, please contact the Service Center.
Notice
Cooling water additives
Additives in the cooling water for antifreeze or corrosion protection can have a negative impact on the
heat transporting properties. The machine can overheat. Only operate the machine with the contractually
agreed cooling water quality.
It must be ensured that the generator is only switched on if the water flow is working.
Provide a monitoring device for the operation of the water circulation.
4.2 Mounting
Mounting position:
The generator is designed for operation in horizontal position only.
Deviation from horizontal position may be permitted within the limits of the technical specification.
Provide correct alignment to the driven equipment. Alignment has to be checked after the components
are mounted in their final position.
Rigid mounting:
Take care of an even ground to avoid twisting of the housing when tightening the generator; if necessary
use adequate underlay for adjustment.
Resilient mounting:
We recommend resilient mounting in order to isolate structure-borne sound.
Observe the weight of the generator as well as stimulating frequencies that occur within the speed range
(possible resonance) and provide coordination with the technical data of the coupling.
General guideline for mounting, alignment and coupling:
The assembler of the drive train has to regard and coordinate correctly:
- type of mounting (rigid or resilient)
- type of coupling (tolerable misalignment and forces due to misalignment; see technical data sheet of
the coupling used)
- permissible forces at the generator shaft (see technical data of generator)
- max. permissible vibrations according to ISO 10816-3 (see table A1; recommended value according to
level A/B; max. acceptable level B/C)
- possible displacement at operation with resilient mounting of generator and/ or gear box
Above mentioned requirements shall be met at all operation conditions.

At resilient mounting the alignment shall be optimized for the mainly used operation range (speed and
torque).
A maximum horizontal and vertical displacement each of 0.5 mm is to be observed if the coupling
manufacturer specifies nothing different.
A protocol of the alignment has to be established (angular and parallel offset in horizontal and vertical
direction; see sample in Appendix A).
4.3 Coupling
The rotor of the generator is dynamically balanced. The balancing mode is indicated on the shaft end face
(H = half key, F = full key, X = plain shaft).
Take care of the according balancing mode of the coupling used!
Use couplings suitable for the misalignment according to the mounting conditions.
Elastic couplings are recommended; take care of correct design to avoid oscillation due to torsional
resonance.
Provide an electrical insulation within the drive train.
Otherwise shaft current could flow into the machinery coupled (e.g. gear box)
and damage their bearings. Check the isolation resistance of the coupling.
All rotating parts have to be covered with protection against accidental contact.
Fitting of couplings onto the shaft extension:

Observe the instructions of the coupling manufacturer!
First the shaft end must be cleaned carefully (removal of conservation coating) and then greased.
Do not use emery cloth.
Couplings have to be fitted.
- by means of a suitable hydraulic device or
- with the aid of a mechanical fitting device
For this purpose the threaded centering hole in the shaft end can be used.
The fitting of the coupling by means of tapping with a hammer is not permitted because of the risk of
bearing damages.
4.4 Electrical connection
Connection must only be made by an expert and in accordance with the valid safety
regulations.
The relevant installation and operating instructions as well as national and international
rules and the utility’s guidelines have to be observed.
If the generator is provided with a desiccant this has to be removed during commissioning.
Observe data on the nameplate!
Observe mains voltage, frequency and phase sequence!
Observe internal connection if selectable (star, delta)!
Observe the wiring diagrams!
Removing the brush blocker:

The brush blocker lifts the brush from the slipring to avoid standstill marks. At the same time the brush
wear indication is triggered.
Remove the brush blocker and put the brush onto the slipring for commissioning.
2 3 1 4
brush
spring carrier
cable tie
brush blocker (rounded area on top under the

brush lug)
schematic of a mounted brush blocker
Procedure:
- Remove the cable tie.
- Remove the spring carrier from the brush pocket. Push the spring carrier with the lug to the brush and
push it out upwards.
CAUTION
The spring carrier is prestressed. It can jump out of the brush pocket. There is risk of injury. Pull the
spring carrier out of the brush pocket carefully.
- Hold the brushes and remove the brush blockers. Keep the brush blockers for later reuse.
- Insert the brushes into the brush pocket until they lay on the slipring. Be careful in order to not damage
the brush.
- Reinstall the spring carrier.
An installation of the brush blockers, for example when the machine shall be stored, is done in the
reverse order.
Grounding:
A terminal for connection of the protective conductor is provided inside each of the terminal boxes. In
addition the generator housing is provided with an earth terminal to provide equipotential bonding of
locally neighboring components (corrosion protected with special conductive coating; does not have to be
removed). Auxiliary parts of the generator (e.g. air cooler) are connected to the generator housing with
connection bonds. Check their correct condition.
Power contact surfaces shall be cleaned and finished to ensure optimal electrical contact.
Tighten all contact screws with the correct tightening torque: see Appendix B and technical data or
adhesive label inside the terminal box.
Minimum clearance between live parts (e.g. cable lugs) and live parts to ground is to be regarded
according to the rated voltage:
UN [Vrms] 550 750 1100 2200 3300

Clearance [mm] 8 10 14 30 36
Designed rated voltage for terminal boxes for generators up to 690 V nominal voltage
stator terminal box:1 kVrms; rotor terminal box: 3 kVrms)
The terminal boxes must be free of dust, moisture and foreign bodies.
Provide correct sealing of the cable entries; close unused cable entries to protect the terminal box against
dust and moisture.
Connection of additional devices (e.g. RTD sensors, heater, brush monitoring, tacho generator):
General:
Observe the connection diagram and adhesive labels!
The plant assembler is responsible for the correct installation (e.g. separation of signal cables and power
cables, shielded cables where required).
The instructions of the plant assembler are to be regarded in addition to these instructions, especially
concerning electromagnetic compatibility.
Encoder:
The encoder usually is mounted isolated from generator ground and generator shaft; it is grounded by a
separate lead (see appendix). The use of this grounding as well as the use of a cable screen has to be
specified by the inverter manufacturer according to his EMC conception.
Observe the applicable wiring diagram and the instructions of the inverter manufacturer concerning the
conception of grounding and handling of cable shields in order to obtain electromagnetic compatibility and
to observe the safety aspects.
4.5 Trip levels for space heaters
We recommend the following trip levels for the space heaters to prevent water from condensing inside the
generator.
Activation:
- nacelle temperature lower than +5 °C and generator not in operation
- winding temperature < nacelle temperature plus +5 K and generator not in operation
Deactivation:
- nacelle temperature greater than +8 °C and generator not in operation
- winding temperature is equal to nacelle temperature plus +8 K and generator not in operation
- generator in operation
Use the same trip levels for the slipring heating when a slipring heating is installed inside the machine.
You can use different trip levels at your own responsibility. If you use different trip levels, then choose trip
levels that are suitable to prevent water from condensing inside the machine. Regard, that condensed
water can enter and weaken the insulation. Condensed water can cause corrosion as well.
4.6 Test of insulation
To be regarded in general:
Possibly existing overvoltage suppressors of the generator (depending on individual design) would
invalidate the test results. In this case the overvoltage suppressors have to be disconnected during the
measurement.
For insulation testing of the rotor it is necessary to separate the inverter from the rotor, as otherwise the
test voltage causes damages to the inverter.
Insulation resistance of the windings:

Insulation resistance is to be measured before energizing (phase to phase and phase to ground).
Especially after longer periods of storage or standstill the function of the insulation system can be
affected. Humid windings might cause creeping current, arcing and ruptures.
Minimum insulation resistance (measured at a winding temperature of 20 °C; test voltage 1000 V DC):
Stator winding and rotor winding: 100 megohms (value according to IEEE Std 43-2000, “Recommended
Practice for Testing Insulation Resistance of Rotating Machinery”)
In case of lower value the machine must not be energized; the winding has to be dried; see chapter 5,
Maintenance. If the drying procedure cannot generate the required insulation resistance: please contact
the manufacturer.
High voltage test of windings:

A high voltage test has not to be carried out during commissioning.
The generators are tested at the manufacturer’s test field according to IEC 60034; repetition tests are not
necessary.
When carrying out a repetition test use as a test voltage:
Test voltage = (2•Ur + 1000 V) •0.8 during 1 min
4.7 Rotational direction
General:
Terminal identification of AC machines according to IEC standard:
If the alphabetical sequence or natural sequence of the terminal identifications corresponds with the time
sequence of the phases, the machine shall have a clockwise rotation. This rule applies to all machines,
independent from the intended direction of rotation.
Counterclockwise rotation is effected by changing the phase sequence of the supply voltage applied.
In general the generator is intended for one operational direction of rotation (see
technical documentation and marking plate on the generator).
Change of the operational direction of rotation in this case: contact the manufacturer
of generator and inverter; it might cause extensive modifications.
Some types of generator are suitable for both directions of rotation (“bidirectional design”; see technical
data). In this case the generator is delivered for a preferred direction of rotation according to customer’s
demand: brush grinding direction and, if applicable, position of 2- layer grounding brushes. Change of the
operational direction in this case: brush grinding and, if applicable, positioning of 2- layer grounding
brushes has to be carried out according to the new direction of rotation (see 5.3.3 Renewal of brushes).
Air cooled version: provide correct rotational direction of the forced ventilation (see marking plate on
generator).
4.8 Lubrication
General:
In some cases an abnormal bearing noise can be heard for a short period in the course of running-in.
This is caused by the dynamic viscosity of the bearing grease. This bearing noise is not critical as long as
the operating temperature of the bearing is not increased.
After storage time up to 6 months:

No special precautions are recommended for commissioning. The generator is delivered greased ready
for operation. Regreasing is only necessary within the intervals given in chapter 5 Maintenance.
After storage time 6 months up to 2 years:
Manual regreasing shall be carried out with twice the grease quantity as required for periodical
regreasing. Regard the operational and safety instructions given in chapter 5 Maintenance.
After storage time more than 2 years:
Manual regreasing shall be carried out with 4 times of the grease quantity as required for periodical
regreasing. Regard the operational and safety instructions given in chapter 5, Maintenance.
If the generator is equipped with an automatic regreasing unit:

The regreasing unit is to be activated during commissioning! It has to be adjusted so that the
specified grease quantity is delivered during operation of the generator (see marking plates
on the generator and technical documentation).
4.9 Check before commissioning, summary
Check whether the bearing lock has been removed (if used)!
Observe data of nameplate!
Check whether sliprings are clean and free of grease!
Brush blocker removed, brushes installed, spring carrier installed and engaged
Check whether voltage and frequency of the generator comply with the mains data!
Check line phase sequence of generator as well as of motor for forced ventilation!
Check insulation resistance of the stator and rotor winding!
Check insulation of the coupling between generator and gear box!
Check correct alignment!
Check coupling and rotating parts (correct installation, correct covers against accidental contact)!
Check correct tightening torque of electrical connections!
Check correct tightening torque of mechanical connections!
Check whether protective measures have been taken!
Check whether monitoring devices are connected and adjusted according to the specifications
(especially temperature sensors and brush wear monitoring)!
Water cooled generators: check whether the coolant circulation is working and if coolant is equipped
with the suitable antifreeze!
Air cooled generators: check whether the forced ventilation is working!
4.10 Check during and after commissioning
- Check vibration free operation of the generator and the tacho generator.
After several hours of operation:

- Check brushes:
Brushes must exhibit a smooth and glossy surface over min. 90 % of the contact area.
- Check sliprings:
The sliprings must not exhibit any traces or wear such as: scores, coloured dots or burn marks.
(After several weeks of operation they shall exhibit a uniform colouring within the brush contact area.)
- In case of resilient mounting the correct alignment shall be checked again after commissioning
including some hours of operation.
After commissioning the first maintenance interval for this check is maximum 4000 h (instead
of 8000 h for following periodical intervals); see table in chapter 5.10.
Maintenance
5 Maintenance
Low voltage generators have dangerous live and rotating parts and hot surfaces.
Observe high acoustic noise level and use protective devices according to the relevant
regulations. All maintenance work is to be made by qualified, responsible specialists.
An inadequate proceeding can cause severe damages to persons and property!
The maintenance intervals given here (and in the technical documentation) are based on the worst case
of operation conditions of the wind energy plant usually to be expected within the scope of the technical
data of the generator.
In case of extraordinary high stress (dirt accumulation, frequent switching, frequent fault shutdown,
excessive coasting operation) additional maintenance measures have to be provided according to the
actual circumstances.
After every maintenance job the work carried out has to be documented and the file
shall be kept and shall be available together with the service life file of the power plant.
Traceability of correct maintenance is mandatory in case of warranty claim.
Works beyond the maintenance jobs described below are not allowed to be carried out
on the generator; in this case the warranty claim becomes invalid.
In case of abnormal observations (e.g. vibration, noise), in case of failures or exceptional conditions
which represent an electrical or mechanical overloading of the machine an appropriate inspection has to
be provided. These inspections are to be discussed with the manufacturer.
5.1 General expertise
At each maintenance interval the generator and the complete drive train shall be checked for abnormal
noise or vibrations during operation and proper operational conditions in general.
5.2 Bearings and lubrication
Data applicable for the generator (regreasing intervals, type of grease and grease quantity):
See marking plates on the generator and technical documentation.
The bearings are equipped with an automatic grease quantity control used to segregate the used grease.
Overfilling of the bearing chambers is not possible since the used grease will be thrown off by a rotating
disc in the outer grease chamber through an aperture in the end shield in case of an extended regreasing
For segregation and removal of the used grease the generator is equipped with either with grease
collecting chambers or grease removal rams (see version on dimensional diagram).
Depending on the individual design of the generator (see dimensional diagram) regreasing is carried out:
- manually by means of a grease gun through the nipples provided on the end shields
- automatically by means of an automatic regreasing unit
Maintenance
To be observed when regreasing manually:

Only use clean grease. Grease nipples have to be cleaned before greasing.
In some cases an abnormal bearing noise can be heard for a short period after regreasing, caused by the
dynamic viscosity of the bearing grease. This noise is not critical.
Regreasing during rotation only! We recommend to carry out regreasing at a low

rotational speed, e.g. in idling operation of the wind turbine.
Risk of accident! Pay attention to rotating parts!
Only use of the grease type as specified is permissible.
Observe regreasing intervals and grease quantity!
Extending the regreasing intervals endangers the bearings.

It is permissible to shorten the regreasing intervals if the grease quantity is adapted accordingly.
In some cases also an alternative type of grease (different from original grease filling) is released by the
manufacturer. If the type of grease shall be changed to this alternative type special instructions have to
be observed; those are available on request.
In case of automatic regreasing unit:

Check the adjustment parameters of the regreasing unit.
The fill level of the grease in the container has to be documented in the maintenance file. It has to be
checked (by comparison with the level documented at the last maintenance period) if the regreasing unit
had worked properly. Ensure that the remaining grease quantity is sufficient until the next periodical
maintenance work.
In case of a malfunction (grease quantity consumed is not in accordance with the value adjusted):
Before installing a new regreasing unit the missing grease quantity has to be applied by manually
regreasing.
The used grease must be removed after regreasing. If this is not done, the grease piles up and the
bearings are overheated (for disposal of used grease regard the environment and health precautions
chapter 7 Environment and health precautions).
- Generators with grease removal rams (see sample photo in appendix):

Removing of used grease is carried out by pulling the ram at the bearing to the stop several times.
- Generators with grease collecting chambers:

These chambers are to be dismounted and emptied at generator standstill.
Grease collecting chambers made of plastic according to sample photo in appendix: These can either
be emptied or substituted by a new one (spare part) while the filled box can be disposed easily.
Change of the plastic box is only necessary if the quantity of regreasing is higher than the remaining
space within the box.
Check the ducts to the grease chambers for clogging by waste grease. Remove any waste grease.
After a longer period of standstill it is recommended to regrease the bearings during

commissioning, similar to the instructions in chapter 3.4 for long term storage.
Maintenance
5.3 Slipring device
General precautions when working at the slipring device:

The slipring chamber is only to be opened when the generator is switched off and at standstill!
Generator has to be disconnected! Ensure that the system is de-energized!
The system has to be protected against unintentional restarting and unintentional rotation.
(Phase designation of the main brushes and grounding brushes: see Appendix A)
A general declaration of the actual brush wear versus time is not possible due to technical reasons.
According to experience an operating time of typically 18 months is achieved, correct operation and
maintenance provided.
5.3.1 Precautionary maintenance
You can find the maintenance interval applicable for the slipring device of the
generator in the table in chapter 5.10 (usual design: 8000 h of operation time).
If the instructions below are observed a trouble-free operation until the next
maintenance point is ensured.
List of maintenance work at the slipring compartment:

- Check if the length of the brushes is sufficient for operation until the next regular maintenance work.
Check if the brush wear of the brushes is reasonably similar.
The length of each brush has to be documented!
- If necessary renew of the brushes (see 5.3.3)
- Cleaning of the slipring compartment (and in case of the attrition filter)
- Check if the brushes can slide unhindered within the brush holders.
If necessary, remove dust or cinder layers from the brush holder sliding surfaces
- Check if the cords of the brushes have enough space to move due to future brush wear
- Visual check of the slipring surfaces and the surfaces of the brushes for grooves
- Check the electrical function of the wear indicator switches
Maintenance
Planning the next brush change

In order to plan the next brush change, you have to measure the usable length of the brush and, together
with the expected brush wear, calculate the remaining operating time.
The length of a new brush is 100 mm. A wear notch is located at 19 mm remaining brush length indicating
the wear limit. At this point the bracket at the brush triggers the wear indication.
Caution
When the wear indication is triggered, the machine may be operated under load for maximum 500 more
hours. Severe damages on the slipring unit can be the consequence
Ensure that the superimposed machine control meets these operating limits.
Measure the remaining length of a brush according to the following picture.

4
2
1 19
usable length
wear notch
total length of a new brush
3 Length to measure
You get the usable length when you subtract 19 mm for the wear limit from the measured length.
The mean wear of a brush is about 5 mm/1000 hours.
Note
Environmental influences like heat or moisture can result in increased brush wear. The wear limit of a
brush is reached earlier then. Record the length of each brush at every maintenance job. With the record
you can estimate the degree of the environmental influence and regard that for the next change of the
brushes.
The remaining operating time can be calculated by: usable length [mm]/wear [mm/h]
So the operating time of a new brush is:
(100 mm – 19 mm) / (5 mm/1000 h) = 81/5 mm • 1000 h = 16200 hours
Note
Small differences in the lengths of the brushes are not unusual due to operational conditions. If there are
greater differences of 15-20 mm there could be a damage of the slipring surface. In this case contact the
Service Center.
After calculating the remaining operating time, you have to decide whether you want to wait until the next
maintenance job or plan an additional maintenance job or change the brushes immediately.
Maintenance
Checking the brush surfaces

The brushes are to be checked if they wear signs of damage and if the surface is in proper condition:
After normal operation they shall exhibit a smooth and glossy surface over the entire contact area.
Checking the slipring surfaces

The sliprings are to be checked if the track wears signs of damage. After normal operation they shall
exhibit a uniform colouring (oxide layer) within the brush contact area.
Appearance of grooves is pointing at inadmissible operating conditions (e.g. dirt accumulation).
Local scorch marks can be the result of short circuit current or lightning current.
In such cases the sliprings have to be replaced by a service staff authorized by the manufacturer.
The sliprings must be kept clean and free of grease.
Checking the spring carriers

Perform a visual inspection of the spring carriers on every maintenance job. Replace spring carriers, if
they show any signs of mechanical damage or corrosion. Replace all spring carriers at the same time to
ensure equal pressure on all brushes. Replace spring carriers after a maximum operation time of
10 years.
Remove the spring carrier in the following order:

1. Push the spring carrier with the lug towards the brush
2. Pull the spring carrier out upwards
CAUTION
The spring carrier is prestressed. It can jump out of the brush pocket. There is a risk of minor injuries. Pull
the spring carrier out of the brush pocket carefully.
The installation of a spring carrier is performed in the opposite order. A spring carrier is engaged when
installed correctly. Take care that the spring carrier is engaged.
Maintenance
5.3.2 Instructions for cleaning the slipring device
The slipring compartment is ventilated; the outgoing air duct might be equipped with an air filter unit to
collect the brush attrition (occasionally included in the scope of delivery; depending on individual design).
The enclosure and all equipment installed (and the air filter if any) have to be cleaned within the
required intervals. If this is not observed, there is a danger of creepage currents and flashovers.
Congested or damaged filters are to be renewed. Regard that the brush attrition is flammable.
Observe the environment and health precautions in chapter 7).
How to clean the slipring cabinet:

Tools and auxiliary devices to clean the closed slipring cabinet:
- ring spanner, open end- and socket spanners and Allen wrenches of different sizes
- working light
- vacuum cleaner with flexible suction hose
- brushes (of different sizes)
- clean and lintless cloth
- dust mask and protective goggles
- released cleaning agents: Rivolta S.L.X.-Top or 100 percent alcohol
Proceeding:
- Unscrew cover on the servicing opening.
- Remove the brushes from the brush pocket, so that no cleaning agent can remain between the brush
and the slipring.
- Remove the carbon dust on brush holders and sliprings with a big brush. Accumulations of carbon
dust have to be removed from the enclosure with the vacuum cleaner immediately.
- Adhering dust around the micro-contact switches and the insulating rings (between the sliprings) as
well as around the brush connecting wires has to be removed completely with a brush or a clean,
lintless cloth and vacuumed.
- Remove the residual dust on the slipring body as well as in the complete slipring enclosure –
especially in the edges and gaps.
- Renew or clean air filter mats.
- Remove the dust accumulated on the bottom of the slipring enclosures completely by means of a
vacuum cleaner.
- Clean insulating and side surfaces of the slipring and the brush bridge and also the track of the slipring
with a moistened cloth after the dry cleaning. Only use the released cleaning agents for moistening.
Others can have an influence on the surface oft he slipring or damage the brushes. Use the cleaning
agent economically and only after dry cleaning as they can emulsify with the brush attrition to a pasty
mass that smears when wiped of.
- Check the correct placement of the brushes, the springs, the brush cords and the cabling of the wear
monitoring switches to ensure that no collisions can occur due to future brush wear.
- Tighten electrical connections within the compartment.
- Close the servicing opening of the enclosure.
Maintenance
Do not use any tools causing damages to the slipring surface at improper use. No fluid solvents (e.g.
cleaner solvent) should be used for cleaning, as those will emulsify with the carbon brush dust to a pasty
mass which smears when it is wiped off.
Special care is required on the creeping distances at following locations:
- Brush holders
- Monitoring switches on the brush holders
- Brush holder studs
- Insulation surfaces of the slipring body
- Leads on the sliprings (front end of the slipring body).
Maintenance
5.3.3 Renewal of brushes
The technical features of the brushes have been adapted to the application.
Only the specified original spare parts are allowed to be used!
In case of using alternative types of brushes the warranty claim becomes invalid.
Even though the spare brushes are delivered in a pre-formed version according to the
diameter of the slipring:
When mounting new brushes they must be carefully seated to obtain correct electrical
contact!
How to seat new brushes:

Grinding is carried out by pulling an abrasive cloth (grain size 180) under the brushes while they are
pressed down with their springs. Grinding can be carried out in two ways:
- either
by pulling the abrasive cloth manually under the brush.
brush
Observe that the abrasive cloth is guided following the
slipring outline.
Finally the abrasive cloth shall be pulled only in the
slipring
direction intended for operation; see sketch.
Abrasive Direction of grinding acc.to

cloth rotational direction intended
- or
with the aid of shaft rotation (= recommended
brush
procedure; used in manufacturing):
The abrasive cloth has to be placed round the sliprings
and fixed with adhesive tape. Rotate slipring acc.to
slipring rotational direction intended
The rotor then shall be rotated in the intended direction
of rotation (see marking on the generator) by idling of
the wind generator. Abrasive
cloth
Risk of accident! Pay attention to rotating parts! Do not touch rotating parts.
After standstill: Before continuing work on the parts the system has to be protected
against unintentional restarting and unintentional rotation.
Maintenance
Grinding procedure for the main brushes:

Use an abrasive cloth with grain size 180. The grinding procedure has to be continued until approx. 90 %
of the contact face is lying on the slipring. This has to be checked by visual inspection of the contact face
(new brushes are provided with several transverse grooves to accelerate the process of running in).
Grinding procedure for the grounding brushes:

- First grinding step:
Use an abrasive cloth with grain size 180. The grinding procedure has to be continued until approx.
90 % of the contact face is lying on the slipring. This has to be checked by visual inspection of the
contact face.
- Second grinding step especially for the grounding brushes:
The grounding brushes have to be finished until a smooth surface of the contact face is obtained.
This can be carried out:
either by finally using a very fine abrasive cloth (grain size 400)
or by rotating the machine without any abrasive cloth, while the grounding brushes are additionally
pressed down with a light force of your thumb
Final works:
Finally carefully clean the brushes, brushholder and sliprings from brush attrition and grains from the
abrasive cloth. Especially the brush contact surface has to be cleaned from residual grains from the
abrasive cloth. Check if the brushes can move easily within the brushholder.
Finally check the electrical function of the grounding brushes (see 5.9) and the wear indicator switches.
When mounting new brushes, take care that:

- the connecting cords and cable lugs are placed in the same way as ex works (see Appendix A)
- the litz wires of the brushes are laid straight, so that the litz wires of different phases and of the
earthing do not touch (see Appendix A)
- the screws of the cable lugs are tightened correctly (tightening torque: Appendix B)
It is necessary that the cords have enough space to move when the brushes are
moving due to future brush wear.
Improper cable laying can cause insufficient contact pressure when the brush is
wearing; this causes severe damage of the slipring device.
Final check after a short period of running (at least 10 minutes):

After a short period of running: (operation or idling) the surface of the grounding brushes and at least 1
main brush shall be checked again: They shall then show a smooth and glossy surface over min. 90 % of
the contact face.
Maintenance
5.4 Others
In addition to the regular maintenance works according to chapter 5.1, 5.2 and 5.3 additional
maintenance work is mandatory to be checked at every 8000 h maintenance interval:
- the correct alignment of the machine and condition of the coupling (including monitoring of the
measurement results; see sample of an alignment protocol in chapter Appendix A)
- vibration of the drive train
- acoustic noise of the bearings
- the tightness of mechanical connections
- the tightness of electrical connections (tightening torques see chapter Appendix B)
- the cleanliness of terminal boxes
- cleanliness of the air-flow channels
- if applicable: readout of the tacho generator memory (diagnostic system)
- correct function of the protection circuits: correct processing of the generator signals (temperature
sensors, brush monitoring switches) within the control system of the plant
5.5 Longer period of standstill of the wind power plant
Special precautions during a longer period of standstill: In general:

follow instructions in chapter 3.4.
It is recommended to operate the drive train with a low idling speed to prevent standstill marks in the
bearings. In this case the brushes must be removed in order to avoid excessive brush wear.
Special precautions after a longer period of standstill (before starting):

Observe the applicable points of chapter 4 (Installation and commissioning), e.g. the insulation resistance
of the windings is to be measured before energizing (details see chapter 5.6 Windings).
Generators with an automatic regreasing unit:

Depending on the time of standstill the grease within the regreasing unit could be segregated.
In this case the grease has to be exchanged:
- loosen the lubrication lines at the bearing units
- switch the regreasing unit to manual operation until the storage tank is emptied
- remove remaining rests of grease and fill in new grease
- switch the regreasing unit to manual operation until new grease appears
- reassemble the lubrication lines and switch the regreasing unit to regular operation
Maintenance
5.6 Windings
(Usually no maintenance work required)

After a longer period of standstill and inadequate ambient conditions the insulation resistance shall be
checked: Minimum insulation resistance of stator winding shall be 100 megohms
(measured at a winding temperature of 20 °C; test voltage 1000V DC; see 4.6).
In case of insufficient insulation resistance the windings have to be dried before energizing the generator.
Drying can be carried out by feeding the winding with a single phase AC current (max. 50% of nominal
current; in case of rotor winding: not to be applied via the slipring device!). Winding temperature should
be up to 80 °C and be kept for several hours.
5.7 Speed sensor (encoder)
General types: usually no maintenance work is required.

(Types with an integrated diagnostic system: The memory shall be read out regularly according to its
technical description to check correct function.)
If control problems should occur check the encoder:

- Encoder version with coupling:
If the isolating spacers are worn control problems will occur. In this case they have to be renewed. The
cause of the wear might be an incorrect alignment between generator and gearbox thus causing
displacement and vibration at the encoder coupling. Check alignment and correct if necessary.
To be observed when working on the encoder:
The encoder coupling has to provide constant velocity and electrical isolation from the generator shaft
(by means of the isolating spacers). This isolation must not be shortcircuited in any way; otherwise
bearing currents could damage the encoder.
The correct alignment of the encoder with the generator shaft is adjusted by the manufacturer. Due to
the construction changing of the encoder is possible without any alignment work.
If the end shield of the slipring compartment should be unscrewed this alignment is no
more valid! In such a case alignment (deviation < 0.03 mm) has to be provided by means
of special equipment; contact an authorized service partner.
- Encoder version with hollow shaft:

Check run out of the shaft; vibration of the tacho generator has to be < 0.03 mm.
In some cases (according to the instructions of the inverter manufacturer) a special adjustment of the
angular position has to be carried out. For this purpose the encoder is equipped with an adjustable
torque support bar (sample photo: see Appendix A).
Maintenance
5.8 Insulation of generator bearings and coupling between generator and gearbox;
insulation resistance: shaft to ground
(Usually no maintenance work required)

Both bearings are equipped with an electrical insulation to prevent bearing damages by bearing currents.
Although the insulation of the bearings is designed for min. 2.5 kV and an insulation resistance in the
megohms- range it is not possible to test this completely on the assembled generator: Due to electrical
conductance of additional parts (bearing caps and the air gap between shaft and bearing caps) the
measuring result would be falsified.
This does not affect the quality of the bearing insulation!
To be observed if assessment of the insulation should be carried out:

- Remove grounding brushes.
- Clean the complete slipring arrangement and the coupling to avoid creepage paths.
- In case of low insulation resistance also check the insulation of the coupling.
- Measurement of the bearing insulation resistance (shaft to ground) shall be carried out with a
measuring voltage less than 500 V (100 V recommended). Only a resistance value below 10 kOhm
might raise a suspicion for isolation problems. In doubt, rotate rotor slightly to different positions to
eliminate effects of dust etc. within the air gaps of the bearing caps that can falsify the measurement.
- Insert grounding brushes again (regard instructions in chapter 5.3).
5.9 Rotor grounding system (grounding brushes)
Check impedance between shaft and housing when finishing maintenance works:
Measurement with a multimeter; max. resistance 1.5 .
Remark:
This measurement does only indicate that the grounding arrangement is present; it is not possible to
evaluate the technical quality of the grounding system (e.g. correct seating of the ground brushes).
Therefore a measurement with a 4-wire milliohm measuring device would be necessary, which is not
required in the scope of the regular maintenance.
In case of doubt contact the Service Center.
Maintenance
5.10 Summary table of maintenance work and intervals
intervals
No. Work to be carried out: see max. remarks
8000 h 40000 h
chapter 4000 h
1 General expertise: abnormal noise 5.1 X 4) X
or vibrations during operation?
2 Manual regreasing of bearings 1) 5.2 2) 3)
(or check of regreasing unit)

3 Check of length of brushes 5.3.1 X 4) X
(incl. documentation of lengths)
4 Check spring carriers 5.3.1 X 4) X Replace, if
necessary 6)
5 Check of brush cords (space for 5.3.1 X 4) X
movement)
6 Visual check of sliprings surface 5.3.1 X 4) X
7 Cleaning of the slipring 5.3.2 X 4) X

compartment
8 Renewal of the brushes 5.3.3 if necessary
9 Tightness of screws in general 5.4 X

Tightness of electrical connections
10 Check: Cleanliness of the terminal 5.4 X
boxes
11 Check: Cleanliness of the air-flow 5.4 X
channels
12 Correct alignment of the machine, 5.4 X 4) X
vibration and condition of the
coupling
13 Rotor grounding system 5.9 X 4) X
14 Documentation of the work carried 5.1 at each

out maintenance
15 If applicable: readout of the tacho 5.7 X
generator memory
16 Forced ventilation motors X if applicable
17 Exchange of coolant 5) according to

coolant supplier
1)
In case of an automatic regreasing unit: Check and documentation of correct function
2)
Regreasing intervals: see marking plates on the generator and technical documentation.
It is permissible to shorten the regreasing intervals if the grease quantity is adapted accordingly.
3)
In case of storage time 6 months up to 2 years: in addition during commissioning; see 4.8.
4)
Only the first interval after commissioning, otherwise periodically maintenance each 8000 h
5)
Design with air-to-water cooling
6)
at the latest after 10 years
Spare Parts
6 Spare parts
Only the specified original spare parts are allowed to be used.

In case of using alternative components the warranty claim becomes invalid.
Detailed listing of spare parts according to the individual type of generator: see technical documentation.
Samples for spare parts:

- Regreasing unit
- Grease collection boxes
- Main brushes
- Grounding brushes
- Fan(s)
- Speed sensor (encoder)
The following information is necessary for correct delivery of spare parts:

- type code of the generator (see nameplate and technical documentation)
- generator number (see nameplate and technical documentation)
- spare part designation (e.g. „main brushes“)
Environment and health precautions
7 Environment and health precautions
7.1 Possibly problematic substances

7.1.1 Brush attrition
Environment and health precautions
7.1.2 Grease
Fire-fighting measures
Suitable extinguishing media: Water spray, foam. dry powder, carbon dioxide (CO2)
Unsuitable extinguishing media: High volume water jet
Special Hazards: In case of fire the following can be released: Carbon monoxide, hydrocarbons
Special protective equipment for firefighters: Standard procedure for chemical fires
Additional Information: Water mist may be used to cool closed containers. In the event of fire and/or
explosion do not breathe fumes
Composition / information on ingredients
Chemical characterization (preparation): Mineral oil, synthetic hydrocarbon oil, special lithium soap.
Hazards identification: No particular hazards known
Handling and storage

Advice on safe handling: No special handling advice required
Advice on protection against fire and explosion: No special precautions required
Requirements on storage rooms and vessels: Store at room temperature in the original container
Incompatible materials: Incompatible with oxidizing agents. Do not store together with food
Further information on storage conditions: None
Exposure controls / personal protection

Additional advice on system design: Not applicable
Ingredients and specific control parameters: None
Respiratory protection: No special protective equipment required
Hand protection: No special protective equipment required
Eye protection: No special protective equipment required
Body protection: No special protective equipment required
Other protection measures: No special protective equipment required
General protection and hygiene measures: Avoid prolonged and/or repeated contact with skin. Remove
soiled or soaked clothing immediately. Clean skin thoroughly after work; apply skin cream
Ecological Information
Information on elimination (persistence and degradability): Product is insoluble in water. May be
separated out mechanically in purification plants
Behaviour in environmental compartments: Ecological injuries are not known or expected under normal
use
Ecotoxic effects: Aquatic toxicity is unlikely due to low solubility
Additional information: Should not be released into the environment
7.2 Recovery of the generator after product life time
The user is responsible for correct treatment and recovery of the product after life time.
The product can be recovered without special precautions by an authorized recycling workshop.
Appendix
Appendix A
Pictures
sample: version with air-to-air heat exchanger, with axial fan
Appendix
Designation of the brushes and litz wire laying

(in principle; details vary for each type)
M4 M3 L4 L3 K4 K3 E2
M2 M1 L2 L1 K2 K1 E1
cable laying with round litz wires cable laying with flat stips
Appendix
Sample of an alignment protocol
horizontal
vertical
angular offset parallel offset
A4: How to seat the brushes (in principle)
abrasive cloth
tape
brush
surface
Appendix
tacho encoder
(hollow shaft type)
grease removal
(removal ram)
grease removal
(one way collection box)
Appendix
Appendix B
Tightening torques for electrical connections
Anziehdrehmoment / Tightening torque

Falls keine anderen Angaben gemacht werden, gelten für Schraubverbindungen
(Schraube und Mutter) folgende Anziehdrehmomente.
If no other data are indicated, the following tightening torques
are applicable for screwed joints (screw and nut).
Anziehdrehmoment für elektrische Anschlüsse Kupferschiene mit Gewinde
Tightening torque for electrical connections copper busbar with threads
M4 2.3 Nm M12 66 Nm
M5 4.6 Nm M16 160 Nm
M6 7.9 Nm M20 330 Nm
M8 19 Nm M24 560 Nm
M10 38 Nm M30 1100 Nm
Schraubverbindung Festigkeitsklasse 8.8 und A4-70

Anziehdrehmomente für Schrauben der Festigkeitsklasse 8.8 und A4-70 (A4-80)
nur in Bauteilen mit höherer Festigkeit (z.B. Grauguß, Stahl).
Screwed joints strength class 8.8 and A4-70
Tightening torque for screws of the strength class 8.8 and A4-70 (A4-80)
only in components with higher strength (e.g. grey cast iron, steel).
M4 2.3 Nm M14 105 Nm
M5 4.6 Nm M16 160 Nm
M6 7.9 Nm M20 330 Nm
M8 19 Nm M24 560 Nm
M10 38 Nm M30 1100 Nm
M12 66 Nm M36 1900 Nm
Schraubverbindung Festigkeitsklasse 5.6

Anziehdrehmomente für Schrauben der Festigkeitsklasse 5.6; 4.6; A2 oder für
Schrauben in Bauteilen mit geringerer Festigkeit (z.B. Aluminium, Blindnietmuttern)
Screwed joints strength class 5.6
Tightening torque for screws of the strength class 5.6; 4.6; A2 or for screws
in components with lower strength (e.g. aluminium, blind rivet nuts).
M4 1.1 Nm M14 49 Nm
M5 2.1 Nm M16 75 Nm
M6 3.7 Nm M20 150 Nm
M8 8.9 Nm M24 260 Nm
M10 18 Nm M30 520 Nm
M12 30 Nm M36 920 Nm
Hinweis: Unbrauchbar gewordene Schrauben sind durch neue
gleicher Festigkeitsklasse zu ersetzen.
Note: Screws which became unuseable have to be replaced

by new ones of the same strength class and type.
Siemens AG
Industry Sector
Drive Technologies and Industry Automation
P.O. Box 4848
90327 NUREMBERG
GERMANY
www.siemens.com/automation

Siemens JF DIFG

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Wind power generator

Operating Instructions / Installation Instructions

Answers for industry.

Document Rev. Release Affected Remarks

Type code of generators; general:

J: internally air cooled

F: LV stator, slipring rotor

frame size (shaft height in mm)

pole number(s) (e.g. „64“= 6+4 pole)

This instruction manual is to be used in connection with the specific

product documentation (diagrams, data sheet, spare part list, etc.)

valid for the individual type of generator.

1 General Instructions for safety and commissioning

1.2 Specified use

- Low Voltage Directive 2006/95/EC:

- Directive „Electromagnetic Compatibility“ 2004/108/EC:

- Directive 2002/96/EC „on waste electrical and electronic equipment (WEEE)”:

(general; details see chapter 3)

(general; details see chapter 3)

(general; details see chapter 4)

1.7 Electrical connection

Observe data on the nameplate as well as the wiring diagram.

1.8 Operation and maintenance

Maintenance work has to be carried out as specified and has to be documented.

2.2 Basic design

Cooling type according to DIN EN 60034-6:

2.3 Generator housing

The generators are equipped with antifriction bearings.

2.5 Slipring device

2.6 Terminal boxes

Design and number of terminal boxes: see dimensional diagram.

General: Technical data: see dimensional diagram and technical documentation.

2.8 Speed sensor (encoder)

2.9 Monitoring devices, additional devices

As a standard the generators are equipped with:

2.10 Operational conditions

Environmental conditions, cooling

Dielectric stress of rotor winding:

Operation at zero power („coasting“) operation at low power:

Notes for operation at low temperatures:

3 Transport and Handling

(environmental conditions during transport according EN 60721-3-2: see technical documentation)

3.2 Check before installation

3.3 Bearing lock

3.4 Storage; long-term storage

(environmental conditions during storage according EN 60721-3-1: see technical documentation)

Water cooled version:

Ensure that the water circuit is totally empty.

Storage time up to 2 years:

Storage time more than 2 years:

4 Installation and commissioning

4.1 Environmental conditions, cooling

(environmental conditions during operation according EN 60721-3-3: see technical documentation)

4.1.1 Version with air-to-air heat exchanger

4.1.2 Version with air-to-water heat exchanger

General guideline for mounting, alignment and coupling:

Above mentioned requirements shall be met at all operation conditions.

Fitting of couplings onto the shaft extension:

4.4 Electrical connection

Removing the brush blocker:

brush blocker (rounded area on top under the

schematic of a mounted brush blocker

UN [Vrms] 550 750 1100 2200 3300