Generator Instruction Manual

Wartsila id : DBAA843102 - a
Contents
1 General Notes and Instructions
Safety precautions
Check list
Maintenance schedule
Customer contact list & Complaint report
2 Drawings
Dimension drawing alternator AZ 12749
Rotor drawing 87485.1
3 Circuit Diagram
Circuit diagram K 850.3.135
Legend to circuit diagram K 850.3.135
4 Operating Instructions
Three-phase synchronous electrical machines series DIG 110...191
Enclosure to operating instructions
5 Regulator Descriptions
Voltage regulator Unitrol 1000-15
6 Bearings
RENK recommendation for lubrication
7 Spare Parts
Drawings 0.2.0, 1.2.2, 2.2.2, 3.0.0.1ms, 4.0.0oRT, 6.0obi
8 Technical Data
Technical Data
Test report 8428299B001
Klüber recommendation
Lifting of generator
Wärtsilä Finland Oy 03/2007

Your order: 4500303586
Your project:
AvK Order no. 8428299B001
General Notes
General Notes
Safety Precautions
Read this advice as well as additional parts can be found in the
the operating instructions documentation.
supplied prior to
commissioning or storage of The documentation, including the
the generator. operating instructions, are part of the
Any works on the generator have to be machine and have to be passed on to the
performed by qualified and trained next user in case the generator is sold or
personnel only. moved.
Any person, working on the generator
has to read and understand these 1.2 Liability and guarantee
operating instructions.
All statements and advice in the operating
instructions are made under consideration
1. General Notes of our present knowledge and experience.
1.1 Important notes for users The technical information

and data, described in this
In the following instructions you will find manual, is the correct state
important information and safety advice for of information at time of
transportation, installation and operation printing. We reserve the right to
for AvK generators of the series DSG and changes due to technical progress
DIG. without changing this operating
instruction. Accordingly, no claims can
AvK generators are designed for different be made from statements and
applications for the use on land as well as descriptions in this manual.
offshore. Series DIG is dimensioned for a
nominal voltage bigger than 1 kV, DSG for
a nominal voltage up to 1 kV. Please refer We will not be liable for any damages or
to the rating plate mounted on the breakdowns due to operating mistakes in
generator for design data and as well as in disregard of these instruction or improper
the data of the respective order. repairs.
Any works on the generator has to be We particularly point out, that spare parts
performed by qualified and trained and additional parts not supplied by AvK,
personnel only. The necessary have to be accepted by AvK. AvK will
qualification can be obtained by training or exclude any liability for damages that
courses through the manufacturer. result from the use of spare and additional
Technicians can obtain a special parts that have not been accepted by AvK.
generator training at AvK Germany. The installation or use of foreign products
may possibly change the constructively
The installation should preferably be given design of the electric machine in a
performed by an AvK service technician or negative way, and may restrict the safety
by a specially trained qualified technician. of persons, machine or other values.
The operating instructions are to be kept Any unauthorized modifications and

close to the generator and have to be changes on the generator are not allowed
available for the personnel at any time. for reasons of safety and will exclude any
liability of AvK for resulting damages. If
Please take notice of the safety transformers supplied by the customer
precautions in chapter 2. Further safety shall be installed in the terminal box, AvK
precautions are mentioned in the has to be consulted first.
respective chapters.
The preceding notes do not extend the
The order related data of the generator as terms of liability and guarantee of the
well as the operating instructions for general delivery terms of AvK.
General Notes
AH/e-04-2003/A page 2
Besides these safety notes all local valid
Manufacturer's Address instructions for safety and accident
prevention have to be followed.
AvK Deutschland GmbH & Co. KG
Bunsenstraße 17 Follow all warnings and
D-85053 Ingolstadt advice and act very carefully
in these cases. Inform all
Phone (+49) (0)841 / 792-0 persons working on the
FAX (+49) (0)841 / 792-250 generator about all work-safety
regulations.
All rights reserved. Reprints
or copies - even extracts -
need the permission of AvK. 2.2 Signs on the generator
2. Safety Precautions At particular dangerous points on the

generator you will find safety notes. To
During transportation, installation, avoid damages to persons or values these
commissioning and maintenance, certain safety notes have to be followed very
works might have to be performed on the strictly.
generator, e.g. on feet support, shaft end,
bearings, terminal box, etc. The working
area and area of danger includes the Achtung!
surroundings of the generator and the Betriebsanleitung
prime mover. Im Klemmenkasten!
During normal operation, the working area Vor Inbetriebnahme unbedingt lesen.
should be limited to the operating and
monitoring devices of the switchboard. Caution!
Operating instructions are inside the
Despite taking into consideration all safety terminal box. These must be read prior to
precautions, the generator may be a commissioning.
source of danger, electrically and
mechanically. To avoid damages to The documents for the generator are in
persons and values, all safety precautions the terminal box
have strictly to be followed.
Beside all safety notes in the operating Transportsicherungen.

instruction the local safety precautions and Vor Inbetriebnahme entfernen
rules for the prevention of accidents have
to be followed. Transport Safety Devices
Remove prior to commissioning.
2.1 Description of symbols and advice During transportation the rotor is secured
against shifting. The transport safety
The following symbols are used in the devices have to be removed before
instructions to highlight particular points commissioning.
and actions:
Maschine nicht betriebsfähig!

Warning! Life in danger!
Machine out of order
Danger! This sign is mounted when the installation

of transformers in the terminal box is
necessary. The transformers have to be
installed prior to commissioning. In this
General Notes
AH/e-04-2003/A page 3
case the installation manual for the Unprotected machine parts
transformers is in the terminal box and in may cause severe injuries.
the enclosed documents.
All safety devices like covers, barriers and

E-Teile im Klemmenkasten protections have to be in place and must
be functioning perfectly at all times.
Spare Parts are inside
It is not permitted to operate
the generator with damaged
Spare parts that are delivered with the safety devices!
generator are in the terminal box. The
spare parts have to be removed.
2.3 Safety at site
ABSTANDSMAß-PROTOKOLL For operating the electrical machine the

AM GLEICHRICHTERTÄGER responsibilities have to be determined
clearly and kept, so that no unclear
Mounting-distance test-report is inside situation regarding safety may occur.
The generator must only be operated
when it is in an excellent state and
For the alignment of single bearing according to the design data. Any change
machines it is important to keep the that reduces the safety has to be reported
mounting distance between rotor and to the responsible person immediately.
stator on the NDE of the generator.
The respective report can be found on the Modifications on the
rectifier carrier at the NDE of the machine are only allowed in
generator. agreement with AvK and
these are to be performed
under supervision of qualified
ACHTUNG! personnel.
Vor Inbetriebnahme Öl einfüllen.
Menge und Qualität laut Beschreibung The way to the operating and monitoring
devices has to be free and must not be
Caution! obstructed by any objects.
Fill in oil prior to commissioning!
Please refer to operating instructions of Prior to commissioning and
the sleeve bearing manufacturer for during maintenance works, all
amount and quality. persons in the danger area
have to be warned. They must
Generators with sleeve bearings need oil be ordered to leave the area.
to be re-filled before commissioning. The
instructions from the sleeve bearing After completion of work, the generator
manufacturer are enclosed. must be checked by qualified personnel to
ensure it is in a safe working state.
2.2 Safety Devices
2.4 Safety precautions for maintenance
Special covers are mounted to protect
against mechanical danger (e.g. rotating Maintenance should normally
parts). Protection against electrical danger only be performed when the
is provided by covers and devices against generator is out of operation
over-voltage and over-current. It is not (except for the re-lubrication
allowed to change or dismount any safety of anti-friction bearings). The prime
devices or to put them out of order. mover has to be disconnected.
General Notes
AH/e-04-2003/A page 4
After completion of the maintenance work, They are only used as mounting device
it must be ensured that all protection and for these add-ons.
safety devices are back in place properly.
• The ring bolts can only be used for the
2.5 Special Dangers transport of the separate machine,
they are not designed to lift the
The operator of the machine complete unit (generator and prime
has to take care, that the mover)
rules for fire protection are
kept and the equivalent • For transporting the machine, the
agents for fire extinction are available following devices are permitted:
near the machine and ready for use.
- Cable and chains,
3. Shipping, Handling, Storage
that comply with the local regulations,
3.1 Safety precautions for transport that have a sufficient carrying capacity,
that are in an excellent working condition
Please comply with the local
valid regulations for It is not permitted to use
shipments. cables that are torn or worn.
Cables and chains may not be
knotted. Cables and chains
Warning! must not touch any sharp edges.
Never move loads over
persons! - Lifting devices: cranes
overhead cranes
• The shipment and the unloading of the
generator must only be performed by • Moving the machine over rough
personnel, who are familiar with the ground e.g. rails, by using a haulage
lifting cranes and corresponding car is not permitted. This may cause
devices. damage to the bearings and the
windings. This is especially important
• The lifting devices have to be designed for the moving of the machine within
for the weight of the generator the factory.
(Chapter 3.4).
3.2 Packaging
• Follow the shipping instructions
(pictographs) on the cover of the The material used for the packing of the
generator. generator is made of ozone-friendly
material – like wood. The packaging
• The generator must only be supported depends on the mode of transport used –
on its feet. The support on any other surface, water or air freight.
part is not permitted. That is why the When the transport time is for a longer
generator is delivered with a period, then the generator will be packed
transportation construction. in a protective covering against dust or
humidity.
• For the lifting of the generator, ring
bolts are mounted on the generator 3.3 Checking for Shipping Damage
housing.
We recommend checking the
Ring bolts, that are mounted generator for shipping
on add-on pieces like e.g. the damages and complete
cooler top, must not be used delivery by the time of
to lift the whole machine! delivery.
General Notes
AH/e-04-2003/A page 5
If there are damages on the goods (open
damages) report these to the haulage
contractor at take-over. In this case, the
receipt should only be given under
reservation with a written statement
regarding the estimated amount of the
damage.
If damages that were not noticeable by the

time of delivery (covered damages), are
detected later, they have to be reported
promptly to AvK, latest 6 days after receipt
of the delivery.
3.4 Unloading the generator
The unloading has to be performed in

compliance with the safety precautions for
transport (see chapter 3.1) and the local
safety precautions and rules for the
prevention of accidents.
Please refer to the freight

papers and the data of the
respective order (Rating
plate) for the weight of the
generator.
The weight of the generator is also
written on the rating plate.
3.5 Storage of the generator
After unloading, the

generator and possible
boxes with loose parts have
to be stored until installation,
following the shipping instructions.
Wrapped parts and assessories must not

be unwrapped if the generator is stored for
a longer period of time.
The machine and packages have to be

stored in a safe place, dust-free and dry
(humidity < 75%). Avoid mechanical
vibrations and damages.
If it is planned to store the

generator for a longer period
of time, please contact AvK
for further information.
General Notes
AH/e-04-2003/A page 6
Bunsenstraße 17
85053 Ingolstadt, Germany
Phone: +49(0)841-792-0
Fax: +49(0)841-792-250
e-mail: infoavkin@newage-avkseg.com
www.newage-avkseg.com

Dreieich branch
Benzstraße 47-49
63303 Dreieich, Germany
Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40
e-mail: infoavkdr@newage-avkseg.com
AvK Deutschland GmbH & Co. KG / Service Date: 22.07.2002
AvK Checklist to Order No. Page 2
Customer: .............................................................
Order No.: .............................................................
Generator Type: .............................................................
Operation Hours: .............................................................
Bearing design: Roller bearing o
Sleeve bearing o
YES NO
Replacement of oil: o o
YES NO
Bearing inspection performed: o o
I. Electrical Inspection
Pos. 1.1 - 1.19
II. Mechanical Inspection
Pos. 2.1 - 2.20
III. Test Run
Pos. 3.1 - 3.14
IV. Maintenance Result

Environmental Conditions:
a) Location: building o marine o
b) Atmosperic conditions: dry o high humidity o

dust o salt o
c) Ventilation: unrestricted o adequate o

restricted o inadequate o
Operating Conditions:
a) Site duty: single o parallel o idle o
b) Duty cycle: 24 hours o daily o occasionally o standby o
c) Load condition: inductive o non linear o
d) Operation: manned o unmanned o
Generator Conditions:
a) Dirt content: slight dust o light layer dirt o

thick dust o thick compact dirt o
b) Corrosion: none, very little o steel/iron o

copper o severe o (....................)
c) Engine: Type: ....................

Serial No.: ....................
Fuel: ....................

I. Electrical Inspection
performed Complaints
see page 11
o 1.1 Examination of cable entry and cable shoes o

to main terminal box
o 1.2 Examination of strain relief of connecting power cables o
o 1.3 Check of fixation of transformers installed o
o 1.4 Examination of cable entry and cable shoes o

to auxiliary terminal box
o 1.5 Check of strain relief of connection cables o
o 1.6 Insulation test of stator windings o
o a) Stator winding phase U against ground o

Resistance ............. MΩ Voltage ............. V
o b) Stator winding phase V against ground o

o c) Stator winding phase W against ground o

1.7 Insulation test of stator windings
o a) Stator winding phase U against phase V o

o b) Stator winding phase U against phase W o

o c) Stator winding phase W against phase V o

o 1.8 Resistance measurement of stator o

see page 11
o 1.9 Check and re-tightening of all screws and nuts o

in main terminal box by dynamometric key
o 1.10 Cleaning and examination of insulators for cracks o
o 1.11 Re-tightening of contact screws and nuts on o

auxiliary terminal strip
o 1.12 Resistance measurement of auxiliary windings o
o 1.13 Insulation test of auxiliary windings o
o 1.14 Examination of anti-condensation heater o
............. V ............. A
o 1.15 Insulation resistance measurement of rotor winding
o a) Insulation measurement main rotor o

o b) Insulation measurement exciter rotor o

o 1.16 Resistance measurement of rotor o
o 1.17 Inspection of rotating rectifiers o
o 1.18 Inspection of stator end winding with endoscope o
o Inspection of stator end winding without endoscope o
o 1.19 Inspection of rotor winding with endoscope o
o Inspection of rotor winding without endoscope o

II. Mechanical Inspection
see page 11
Sleeve Bearing Design
YES NO
Oil lubrication system installed: o o
o 2.1 Check of oil level in sleeve bearing o
o 2.2 Check for leakage of sleeve bearings o
o 2.3 Inspection of sleeve bearing with endoscope o
o Inspection of sleeve bearing without endoscope o
o 2.4 Check of oil quantity of oil lubrication system o
o 2.5 Check of oil pressure of oil lubrication system: o
.................... mbar
o 2.6 Check of oil temperature of oil lubrication system o
o 2.7 Check of oil pressure inside the bearing housing o
.................... mbar
o 2.8 Check of lubrication ring o
o 2.9 Check for any corrosion on drive side and non-drive side bearing o
o 2.10 Oil viscosity used: according to ISO VG ................. o

see page 11
Roller/Ball Bearing Design
o 2.11 Relubrication of roller/ball bearing according to operating instructions o
o 2.12 Removal of surplus grease o
o 2.13 Removal of old grease from bearing covers o
Additional Mechanical Checks
o 2.14 Inspection of abrasion of earthing brush o
o 2.15 Inspection of base frame for mechanical deviations o
Mounting of alternator / Check of feet fixation
o 2.16 Visual inspection of the drive coupling o
o 2.17 Check of inlet and outlet airducts for dust and dirt o
o 2.18 Check of inlet and outlet airducts for corrosion o
o 2.19 Cooler / leakage monitoring o
o 2.20 Check of drainage stoppers / drainage for condensation o

water

III. Test Run
see page 11
o 3.1 Check whether earthing switch is disconnected o
o 3.2 Check of bearing noise o
o 3.3 SPM bearing analysis: DE: LR .......... HR .......... o
NDE: LR .......... HR .......... o
o 3.4 Check of oil amount in sleeve bearings during operation o
o 3.5 Effectivity of lubrication ring o
o 3.6 Tripping of temperature protector for check o

of alarm and shut down
o 3.7 Vibration test / Vibration values (mm/s) o
DE: .......... Hor. .......... Ver. .......... Axi.
NDE: .......... Hor. .......... Ver. .......... Axi.
Frame: ............. Airduct inlet: ............. Airduct outlet: .............
Output: ............. kW

see page 11
o 3.8 Check of regulator functions at no-load operation o
a) Exciter current at rated voltage and rated speed:
I1-I1': ............. A
b) Exciter current at rated load:
I1-I1': ............. A
c) Supply voltage: UH1-UH2: ............. V
UH1-WH2: ............. V
WH1-WH2: ............. V
d) Under speed protection: H1 LED off ............. Hz
o 3.9 Check of parallel operation o
Check of distribution of load
Statics adjustment .......... %
o 3.10 Check of overcurrent and short circuit protection trip o
o 3.11 Check of differential protective trip o
o 3.12 Check of exciter monitoring system o
XE2 o
TO 109/110.1 o
o 3.13 Check of generator voltage in parallel operation o
grid voltage min.: ............. kV

grid voltage max.: ............. kV

see page 11
o 3.14 Bearing and winding temperature after continuous o

operation
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________

IV. Maintenance Result
Complaints:
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
o The operation of the alternator can be continued without immediate

elimination of the complaints.
o Electrical and mechanical checks were performed without any

complaints.
o The alternator must be stopped immediately due to the complaints.
Date: ________________ ________________________

(Signature Customer)
________________________
(AvK-Service-Technician)

Bunsenstraße 17
Phone: +49(0)841-792-0
Fax: +49(0)841-792-250

Dreieich branch
Benzstraße 47-49
Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40
AvK Deutschland GmbH und Co. KG Page 1 of 2
Suggested Maintenance Schedule for AvK Order No.:

Customer:
Date:
Pos. A Components Frequency Maintenance Carried out by

1 General alternator check 12 month According to AvK Checklist. AvK
Pos. B Additional components Frequency Maintenance Carried out by

1 Rotor windings 12 month *) The insulation resistance must be checked with a megger AvK
when the alternator has reached ambient temperature.
2 Exciter approx. 25,000 h *) Remove any accumulated dust from the rotating rectifier AvK
and the exciter stator. Check if the electrical connections
are secure.
3 Rectifier assembly approx. 25,000 h *) Remove dirt adhering to the rectifier unit parts. AvK
4 Stator end winding approx. 25,000 h *) Inspect and remove deposits of dust, dirt and grease. Do AvK
not use any abrassive materials or fluids. Use only
electrocleaner.
Caution: In case of heavy winding contamination please

call the AvK Service Department.
5 Protection equipment 12 month *) Check mechanical and electrical connections according AvK
to the supplier´s specification / manual.
6 Space heater 6 month Ensure that the electrical heater is operating to prevent Customer
condensation. Check the power supply as well as the
insulation resistance.
*) Maintenance frequency depends on the operating conditions at site.
Maintenance-e.xls Service / Steller Date: 18.04.2000

AvK Deutschland GmbH und Co. KG Page 2 of 2
Suggested Maintenance Schedule for AvK Order No.:

Customer:
Date:
Pos. B Additional components Frequency Maintenance Carried out by

7 Ball and roller bearings Grease relubrication acc. Check oil or grease for any contamination particles. AvK / Customer
to supplier´s manual
and/or name plate.
6 month SPM bearing analysis. AvK

8 Sleeve bearing: Oil ring 6 month Ensure that the oil ring is rotating freely and picking up Customer
enough oil when the shaft is turning.
9 Sleeve bearing: Oil seals 6 month Check for oil leaks. Customer
25,000 h *) The oil seals must be changed. AvK

10 Sleeve bearing: Complete check 50,000 h The bearing check must be done (according to supplier´s AvK
manual) and the oil seals must be changed.
11 Oil pipes and flanges 6 month Check for oil leaks. Customer
After the first 500 running hours it is recommended to
tighten the screws of the flanges again.
12 Sleeve bearing: Oil level monthly The oil level must be visible in the viewing glass. Customer
(Approx. one third of the diameter.)
13 Bearing earthing brush 3 month Check the earthing brush for abrasion. Customer
14 Dust filter 3 month *) At the appropriate intervals, the filters must be checked Customer
to establish their degree of contamination with dust and
dirt.
15 Cooler 6 month Check the cooler elements and leakage detector. Customer
16 Complete alternator 100,000 h Review with manufacturer for recommendations for full AvK
inspection / overhaul.
*) Maintenance frequency depends on the operating conditions at site.
Maintenance-e.xls Service / Steller Date: 18.04.2000

Customer Complaint Report FM 7.5-14
Kunden- Beanstandungsbericht Page 1 of 1

Distribution List: Customer => AvK Contact person, according to Customer Contact List DA 7.5-1 or
AvK Hompage www.newage-avkseg.com
1.0 General Complaint information

Allgemeine Daten der Beanstandung:
Customer Place of Complained

Kunde
Alternator Einsatzort
Contact Person Customer Customer Fax No.:
Ansprechpartner Kunde Kunden Fax Nr.
Customer Phone No.: Customer Complain No.:

Kunden Beanstandungs - Nr.
Kunden Tel. Nr.
Customer email Type of alternator:

Kunden Email Generator Typ
AvK Order.- Nr.: AvK Serial No.:

AvK Masch. - Nr.:
2.0 Failure description / Fehlerbeschreibung
Defect Part
Defektes Bauteil
3.0 Immediate measure by customer/ Sofortmaßnahme durch den Kunden

Initiated (date) / eingeleitet am:
Successfully completed (date):

erfolgreich abgeschlossen am
4.0 Enclosures / Anlagen

Photos / Fotos others:
sonstiges
Dokumentenname: Revisionsstand:
7_5f14a.doc AvK Deutschland GmbH & Co. KG A vom 09.10.03
Customer Contact List DA 7.5-1
Service and Warranty Claim Handling for AvK Alternators 1 von 2
Technical Service on-site (after warranty):

Products Countries Contact E-mail Phone Fax
All AvK
UK Sarah Nicholls Sarah.nicholls@newage-avkseg.com +44-(0)1780-484 ~767 ~104
Products
All AvK Spain
John Johnson John.johnson@newage-avkseg.com Mobile: +34-(0)629183929
Products Portugal
All AvK France

Rene Moulin Rene.moulin@newage-avkseg.com +33-(0)16074 ~9843 ~9844
Products french speaking North Africa
All AvK Italy

Guiseppe Cinnirella Joseph.cinnirella@newage-avkseg.com +39-(0)2-38000 ~714 ~664
Products
Norway
Sweden
All AvK Denmark
Jan Jakobsen J.Jakobsen@newage.no +47-(0)22-9744~37 ~45
Products Finland
Baltic States
Russia
North America 001-763-528-7301-6
South America
All AvK Direct: 001-763-574 ~5000 ~5082
Mexico Gary O`Malley Gary.b.omalley@newage-avkseg.com
Products Central America TOLL FREE: (1) 800 ~367-2764 ~863-9243
Canada
Australia +61-(0)2-9680 ~2299 ~1545
All AvK
New Zealand Theo Dragonas Theo.dragonas@newage-avkseg.com
Products Mobile: +61-(0)412-886643
South Pacific
All AvK +41 317 408 282
Switzerland Martin Läderach laederach_interplan@bluewin.ch +41 317 408 280
Products Mobile: +41 7920 17561
Dokumentenname:
Revisionsstand:
Customer contact.doc AvK Deutschland GmbH & Co. KG
B vom 30.03.05
Stand: B vom 07.04.05
Customer Contact List DA 7.5-1
Service and Warranty Claim Handling for AvK Alternators 2 von 2
Products Countries Contact E-mail Phone Fax

Singapore Richard Lee, Richard.lee@newage-avkseg.com +65-(0)6794-3737/5 +65-(0)6898-9065
Malaysia
Philippines
All AvK Anthony Tan Anthony.tan@newage-avkseg.com Mobile: +65-(0)979-192-57
Indonesia
Products Thailand Trisno Sumarlin Trisno13@cbn.net.id +62-214601685
Taiwan
Vietnam (Indonesia)
All AvK +86-(0)510-521 ~6212 ~7673
China Jason Xu Jason.xu@newage-avkseg.com
Products Mobile: +86-(0)139-5157-0763
All AvK +81-(0)354-415 ~588 ~590
Japan, Korea Darryl Hanna Darryl.hanna@newage-avkseg.com
Products Mobile: +81-(0)906-386-574
All AvK
India, Nepal R.K. Kapur Avkpower@del3.vsnl.net.in +91-(0)9811196343
Products
Contact for Warranty Claims:

Product Countries Contact E-mail Phone Fax
All AvK +49-(0)841-792 ~163 ~195
Worldwide Norbert Steller n.steller@newage-avkseg.com
Products Mobile: +49-(0)171-221-9453
Issued Approved
am: 30.03.03 30.03.03
von: Norbert Steller Emilia Sandau

Service Manager Assistant Service Manager
Unterschrift:
Norbert Steller Emilia Sandau
Dokumentenname:
Revisionsstand:
Customer contact.doc AvK Deutschland GmbH & Co. KG
B vom 30.03.05
Stand: B vom 07.04.05
Drawings
Circuit Diagrams
Seite 1 Legende zum Schaltbild Nr. Legend to Circuit Diagram No.
Page 1 K 850.3.135 K 850.3.135
B5 Spannungsregler UNITROL 1000 Automatic voltage regulator UNITROL 1000

ACHTUNG: ATTENTION:
ABB Reglerbeschreibung 3BHS116747_E20 See ABB’s wiring diagram 3BHS116747_E20
Rev.: F Rev.:F for detailed AVR connections and
zum Anschluß und zur Einstellung des Reglers adjustments!
beachten!
F1 Schutzschalter für G3 Protection switch for G3
NUR IM STILLSTAND EINSCHALTEN ONLY SWITCH ON AT STANDSTILL
FS1 Schutzschalter für Spannungswandler T25,T26 Protection switch for voltage transformers
T25,T26
NUR IM STILLSTAND EINSCHALTEN SWITCH ON ONLY AT STANDSTILL
33-34,41-42 Meldung 33-34,41-42 Signal contacts
G1 Hauptmaschine Main machine
G2 Erregermaschine Exciter machine
G3 Hilfserregerwicklungen Auxiliary exciter windings
R11 Rotierender Varistor Rotating varistor
T6 Statikwandler für UNITROL 1000 Droop transformer for UNITROL 1000
..../1A 3VA 5P5 …./1A 3VA 5P5
Daten siehe Auftragsdokumentation datas see order documentation
T14,15,16 Stromwandler Current transformer detail
……./…./….A …../…..VA …..Fs…/ …P…. ……./…./….A …../…..VA …..Fs…/ …P….
T25,26 Spannungswandler Voltage transformer detail
......kV/ .....V 10VA Klasse 0,5 ......kV/ .....V 10VA Klasse 0,5
T32 Spannungswandler für G3 mit integriertem Voltage transformer for G3 with integrated
Schutzschalter F1 protection switch F1
F1 - NUR IM STILLSTAND EINSCHALTEN F1 - SWITCH ON ONLY AT STANDSTILL
V1 Rotierende Gleichrichter Rotating rectifiers
X1 Hauptklemmen Main terminals
X2 Klemmleiste für Regleranschluß Terminal strip for AVR connections
X4 Klemmleiste für Heizung, PT100 Terminal strip for heater, PT100
X5 Klemmleiste für Stromwandler Terminal strip for current transformers
ZUBEHÖR ACCESSORIES
Widerstandsthermometer PT100 Resistance Thermometer PT100
Statorwicklung Stator winding
A1 Phase U Phase U
A2 Phase V Phase V
A3 Phase W Phase W
A4 Phase U Phase U
A5 Phase V Phase V
A6 Phase W Phase W
A13 Lager, B-Seite Bearing, NDE
A15 Lager, A-Seite Bearing, DE
H Stillstandsheizung 400V +-10% 1500 W Anti condensation heater 400V+-10% 1500 W
Schnellentregung: Quick de-excitation:

Brücken UH1-24 und WH1-14 öffnen Open bridges UH1-24 and WH1-14
Entregungsschalter: 220 V AC De-excitation switch: 220 V AC

(nicht AvK Lieferumfang) 10 A (not AvK supply) 10 A
Erstellt am: 24.11.06 Issued on: 24.11.06
AvK geprüft von: Diegeler Checked by: Diegeler
Revision Nr.: 0 Revision No.: 0
Operating Instructions DIG
Operating instructions
Three-phase synchronous electrical machines,
Series DIG 110…191 with „COSIMAT N“ voltage regulator
Before installing and starting up this machine, please read these instructions carefully.
Machine Type:___________________ Dimension sheet No.____________________
Machine No._____________________ Circuit diagram No._____________________

CONTENTS
1. Operating and maintenance instruction ………… 3

1.1. Checking for damage incurred during transit ………… 3
1.2. Transport ………… 3
1.3. Storage ………… 3
1.3.1. Preservation ………… 3
Complete machine ………… 3
Shaft end, flange and bright metal areas ………… 3
Bearings ………… 3
Sleeve bearings ………… 3
Ball and roller bearings ………… 3
Cooler ………… 3
1.4. Setting up the machine ………… 3
1.5. Cooling the machine ………… 4
1.5.1. Coolant temperature ………… 4
Direction of cooling air ………… 4
Quality of cooling air ………… 4
1.6. Dust filter ………… 4
1.6.1. Synthetic filter elements ………… 4
1.6.2. Woven metal filter elements ………… 4
1.7. Preparations prior to starting up ………… 4
1.7.1. Removing preservation ………… 5
Complete machine ………… 5
Shaft end, flange and bright metal areas ………… 5
Bearing ………… 5
Sleeve bearing ………… 5
Ball and roller bearings ………… 5
Cooler ………… 5
1.8. Machine drive ………… 5
1.8.1. Belt drive ………… 5
1.8.2. Coupling drive ………… 5
1.9. Aligning the machine ………… 6
1.10. Changing direction of rotation ………… 7
1.11. Electrical connections ………… 7
1.12. Starting up ………… 7
1.12.1. Insulation resistance ………… 7
1.12.2. Operating speed ………… 8
1.12.3. No-load operation ………… 8
1.12.4. Parallel operation ………… 8
1.12.5. Loss of remanence ………… 9
1.13. Power factor regulation ………… 9
1.14. Interference suppression ………… 9
1.15. Operation ………… 9
1.16. Maintenance ………… 9
1.17. Bearings ………… 9
1.17.1. Ball and roller bearings ………… 9
Re-lubricating the bearings …………10
Re-lubrication intervals …………10
Re-lubrication quantity …………10
Lubrication chart …………10
Ball and roller bearing grease …………10
Dismantling the bearings …………11
Assembling the bearings …………11
Monitoring the bearings …………11
1.18. Drying out the machine …………11
Operating Instructions DIG 110...191 page 2

Rev. November 2001
1.Operating and maintenance instructions • Complete machine
Store the machine in a dry, dust-free condition, for

1.1.Checking for damage incurred during transit example heat-sealed in plastic foil into which a quantity
of desiccant has been placed, or ventilated with dry air.
Immediately after receiving the machine, inspect it for Make sure that no moisture can condense on or in the
damage incurred during transit. The transport or machine and its attached assemblies. The machine must
delivering company must be notified of possible not be exposed to vibration while in storage.
complaints immediately, or at the latest within seven days
of delivery (covered by warranty). • Shaft end, flange and bright metal areas
Clean rust and dirt off the bright metal surfaces and
1.2. Transport apply a protective lacquer coating. Make sure that the
coating is not porous.
During transit, support the machine only on its feet. Do
not allow the weight to be taken by any other • Bearings
components.
Sleeve bearings
Lift the machine at the crane rings attached to the stator Drain the oil and apply a corrosion inhibitor to the
housing. Note that crane rings on attached components bearing, for instance Tectyl 511 M in the case of sleeve
such as the cooler assembly must not be used to lift the bearings lubricated with mineral oil. If the bearings are
complete machine. They are intended only to simplify lubricated with a synthetic oil, make sure that the bearing
attachment of these components. materials, the oilcontent and the preserving agent are all
compatible.
In the case of complete machine sets on a base frame,
use only the lifting facilities provided on the base frame. Ball and roller bearings
The crane rings on the electrical machine itself are not To prevent brinelling marks caused by vibration when at
rated for lifting the complete machine set. a standstill, bearings should either be pre-loaded with a
transit keeper or the rotor should be turned once a
If transported over long distances, it is advisable to month to alter the position of the balls or rollers. The
protect the machine against environmental influences by bearing´s grease content should be increased to the
sealing it in a plastic cover together with a quantity of maximum.
desiccant (moisture indicator), so that it remains dust-free
and air-tight. • Cooler
Machines with plain or taper roller bearings, and Drain out the cooling water, clean the pipes, flush
machines in a single bearing design are supplied with through with clean water and dry the complete cooler,
shipping brace. This shipping brace should never be using warm or pre-dried air.
removed until the machine has been set up in its future
operating position on site. Install the shipping brace Check the efficacy of the protective treatment measures
again if the machine is, for instance, to be shipped on or once a year. If ambient conditions are particularly
stored as a separate unit after trials. unfavorable, check at more frequent intervals. If
necessary, repeat the protective treatment.
For transport as a complete machine set, take the
necessary safety precautions, for instance support the
machine set on anti-vibration elements or attach transit 1.4. Setting up the machine
keepers.
The installation site must comply with the machine´s
enclosure rating and be sufficiently large for cooling and
1.3. Storage maintenance purposes. When setting up the machine,
make sure that:
If the machine is to be stored after trial running, note the
following points: • The relevant operation and maintenance safety
regulations are observed
1.3.1. Preservation
• Cooling air can enter and exit freely

Rev. November 2001
• Exhaust gas and heated cooling air cannot be drawn 1.6. Dust filter
in by the machine
If the machine is equipped with dust filters, please note
the following points.
1.5. Cooling the machine
• The cooling air must not exceed the temperature
1.5.1. Coolant temperature stated on the machine´s data plate.
Unless otherwise specified, the machine is built to run at • At the appropriate intervals, the filters should be
a coolant temperature of up to 40°C and at an checked to establish their degree of contamination
installation height of up to 1000 meters above mean sea with dust and dirt.
level. Please refer to the machine´s data plate for
coolant temperature and power rating. To ensure that the machine´s windings cannot overheat
as a result of blocked filters, three temperature sensors
Coolant temperatures higher than stated on the are provided in the stator winding. These sensors must
machine´s data plate will result in power loss. be connected to the warning system.
Coolant temperature Max. available power 1.6.1. Synthetic filter elements

45°C 96%
50°C 92,5% These are dry-type filters and must be cleaned at regular
intervals, which depend on the amount of dust and dirt
If the machine is ordered to run at coolant temperatures trapped by the fliter. FIlter elements can be cleaned with
higher than 40°C, this is shown on its rating plate compressed air, water at a temperature not exceeding
together with the alteration in power rating. 50°C or a liquid detergent, but it is often a more
economical proposition to renew them.
1.5.2. Direction of cooling air
Comply with all relevant environmental protection and
The machine is cooled by an integral fan dependent on safety regulations.
the direction of rotation, mounted on the shaft. It draws
cooling air through the machine and expels it at the fan 1.6.2. Woven metal filter elements
side.
These are supplied dry, that is to say not wetted with oil.
To ensure proper cooling, make sure that the direction of They can either be operated dry or sprayed with special
fan rotation is as indicated by the arrow on the machine. filter oil. If the filter elements are sprayed with oil, comply
with the relevant environmental protection laws when
If it is intended to use forced cooling, either alone or to cleaning them. They can be cleaned with a high-pressure
support the integral fan, the direction of airflow and
rotation must be correct here too. cleaning unit. Additives to dislodge grease can be used,
provided that they have been checked for compatibility
with the filter material. After cleaning, dry the fliter
Important: elements and if necessary spray the with fresh oil.
The distance between the air inlet or outlet on the
machine and any nearby wall must not be less than the Comply with all relevant environmental protection and
dimension stated below, otherwise ventilation will be safety regulations.
obstructed.
Minimum distance (guide value): Regular cleaning of the filter elements is still needed even
1 x diameter of machine if the electrical machine´s windings are protected against
overheating by built-in temperature sensors. Careful
1.5.3. Quality of cooling air attention to this point will ensure that the machine always
runs cool and reliably.
To extend the service life of the machine, and in
1.7. Preparations for starting up
particular its windings and bearings, it is extremely
important that neither contaminated not aggressive
Pull the protective lasquer coating off the end of the shaft
cooling air be allowed to enter it. An air fliter can be
and the flange, or remove it with solvent. Never clean it
installed if requested by the customer, or can be trofitted
off with emery cloth. Comply with the relevant
provided sufficient space is available.
regulations on environmental protection and safety.

Rev. November 2001
There is a threaded hole on the shaft, to which a puller bearings so that only the specified amount remains in the
can be attached for installing and removing discs or bearing (see chapter on renewing bearings and
couplings. Hammering is not permitted, as this can lubrication plate).
damage the bearings. If the machine is delivered with
shipping brace in position, remove it. • Cooler
If the machine ist of singlebearing design, its rotor is Add water to the cooling circuit and operate it in
delivered attached to the shaft flange and the housing by accordance with the cooler manufacturer´s operating
a steel hoop to prevent axial displacement and is located and maintenance instructions.
in position radially between the shaft and fan housing by
an angle bracket. Both these transit keepers (axial and 1.8. Machine drive
radial) must be removed.
1.8.1. Belt drive
Make quite sure that the radial transit keepers are
removed from the gap only after the rotor has been If the machine is driven by a belt, the machine must be
centered on the drive shaft flange. Failure to do so can ordered specifically with bearings and bearing
result in damage to the exciter machine and the NDS lubrication to match the higher loadings. Most belt-
(Non-drive-side) bearing. driven machines have roller bearings on the input side.
In the case of machines with a steel disc coupling, the The rotor must be ordered with balancing by solid key,
radial transit keepers are screws in the flange bell. They and the grooved belt pulley must be dynamically
must be removed after the machine has been aligned balanced on a smooth mandrel. The belt must run
and its position fixed in relation to the drive input. smoothly, without jerking.
Desired balancing accuracy: = Q 2,5 according to
If the machine was given protective treatment following a German VDI 2060 standard.
trial run, the following measures must be taken:
When flat-type belts or V-belts which have already been
1.7.1. Removing preservation in operation for a fairly long time are removed for
maintenance purposes, they must be replaced by new
• Complete machine ones (in case of hardening).
Check the machine´s insulation resistance. If it is below Important:

the minimum value (see Chapter 1.12.1, Insulation
resistance), the machine must be dried out. The Belts that are tensioned too tightly can put the bearings
procedure is described in Chapter 1.18., Drying out the at risk. For this reason, establish the correct belt tension
machine. with the belt manufacturer or the plant that supplied the
machine, and have checks carried out on site.
• Shaft end, flange and bright metal areas
1.8.2. Coupling drive
Remove the protective lacquer coating with a suitable
solvent. Do not rub it off with emery cloth. Comply with Unless expressly ordered otherwise, the rotor is balanced
the relevant environmental protection and safety with a solid key. The grooved drive elements must
regulations. therefore be balanced on a smooth mandrel.
• Bearings The coupling must be dynamically balanced to an

accuracy of
Sleeve bearings = Q 2,5 according to VDI 2060.
Dismantle and clean the sleeve bearings. The corrosion
inhibiting agent must be removed. (this is not necessary if When installing the coupling on to the shaft end, make
Tectyl 511 M was used and the storage period was fairly sure that no hammer-blows or shocks are transmitted to
short, provided that the bearing is then lubricated with the machine´s bearings. Always use a suitable puller.
mineral oil).
Fill the sleeve bearings with oil as stated on the When pulling the coupling on, comply with its
lubrication plate and in the operating instructions. manufacturer´s assembly instructions. Unless otherwise
stated by the supplier, the coupling half can be heated
Ball and roller bearings up to 80°C. It can then be pushed on to the shaft end
Open the bearing housing and remove the additional easily. Ensure that the drive element is securely located
quantity of grease which was previously added to the

Rev. November 2001
after tightening, and securely clamped against the While checking, turn the coupling slowly through 360°C,
mechanical stop on the shaft. at the same time taking the readings at the individual
dial gauges. Attach one dial gauge radially and two
axially, to compensate for rotor displacement. Refer to
1.9. Aligning the machine the coupling manufacturer´s data as a guide to
permissible deviations from true alignment.
Precise, careful alignment of the machine ensures that it
runs with the minimum vibration, thus extending the
service life of the machine and in particular of the
bearings. This applies to machnies with either flexible or
rigid couplings.
Even slight errors of alignment can rapidly result in

damaged bearings.
It is vital that all the feet are fully in contact. Uneven
undersurfaces cause stresses in the bearings and must be
compensated for by attaching sheet metal strips. Once
the machine is aligned correctly, secure it with dowel
pins. When aligning a machine of single bearing design,
it is important to comply with the reference dimensions
specified on the dimension sheet and the drawing
showing tolerances and clearances included with the
machine. For further instructions, see the chapter on
plain bearings.
On machines with a steel disc coupling, radial rotor
alignment is by means of centering screws inserted into Possible test method:
the centering bell. These screws also act as transit Slowly turn the coupling through
keepers in a radial direction. They replace the 360°C and determine maximum
pressboard inserts otherwise placed in the air gap. deflection of the dial gauge.
Alignment is checked by measuring the distance between
the outer rim of the steel disc coupling and the machined M = dial gauge
inner diameter of the centering bell.
In the case of single-bearing machines with a divide DS
(drive side) end shield, accuracy of alignment is checked
by measuring the air gap.
If the machine has an undivided bearing plate, a

machined end disc is installed at the drive side. The
measurement is then made between the shaft and the
machined inner diameter of te end plate.
Take three measurements in each case, at 120-degree
intervals round the shaft. The results must not vary by
more than 0,2 mm.
This will ensure a uniform air gap beneath all poles and
the correct axial position of the rotor. Check alignment
accuracy at the end of the shaft or at the coupling.

Rev. November 2001
Guide values
Shaft center displacement Shaft tilt Coupling gap*

* Note coupling manufacturer´s data and allow for thermal expansion at the electrical machine and the drive.
If the coupling manufacturer specifies closer tolerances, The machine must be connected up according to the
always comply with them or obtain even lower values if accompanying circuit diagram. The marked earthing
possible. (grounding) screw must be connected to the earth
conductor. Installation is permitted by a qualified
During alignment, remember that the length may electrician only. Comply with the following points:
increase as a result of thermal expansion in the machine.
This change in length is approximately 0,1 ,, per meter • VDE safety regulations or those of the local safety
of machine length and per 10 degrees Centigrade of authorities
temperature rise.
• Local electricity supplier´s guidelines regarding
In all cases, try to approach the ideal clearance values protective measures
as closely as poosible.
• Phase sequence or direction of rotation of machine
Important points to be checked before starting up: field as stated on rating plate
a) have pressboard transit keeper inserts been removed • Correct direction of rotation as stated on the
from the air gap? machine´s data plate
b) Have the aligning screws been removed from the When connecting the cables, make sure that no
centering bell? mechanical forces can act on the machine´s connecting
terminals. This also applies during assembly work.
1.10. Changing direction of rotation Unused cable glands in the terminal box and machine
must be protected against dust and moisture, and closed
Before reversing the machine´s direction of rotation, it is so that they cannot turn. Take up slack at all screw
important that the manufacturer be consulted. contacts and nuts.
In most cases the fan is of a directional pattern and will If current surges or vibration are to be expected, secure
have to be renewed. the cables with cable clips or racks. If the plant is set up
on flexible mountings, ensure adequate clack in the
Note that the rotary field also changes with a reversal in cables.
the direction of rotation.
If the machine is to be used in parallel operation, the 1.12. Starting up

sensing lead plug connections on the regulator (U and
W) must be changed over so that connections U V W on 1.12.1. Insulation resistance
the regulator again receive a right-handed field. The
rotary field will change at the main terminas. After a long period out of use or in storage, the
machine´s insulation resistance must be measured.
1.11. Electrical connections Before starting uf any machine, measure the insulation
resistance of the winding between phases (if the star
point is separate) and between phase and earth. All parts
not subjected to the measuring voltage must be earthed.

Rev. November 2001
Use a maximum test voltage of 500 V DC for all
When measuring the insulation resistance, all secondary and measuring connections. Insulation
connections (main connection, measuring connection, resistance should not fall below 5 MO.
connection to regulator and protection or suppression
circuit) must be disconnected from the winding. 1.12.2. Operating speed
The suppression elements and measuring leads must be The machine´s speed must correspond to the value
disconnected during high-voltage insulation tests and stated on its rating plate. The machine must run
tests with insulation measuring appliances. smoothly, both at no-load and when under load.
Measure at 500 V DC on low-voltage machines (< 1 kV) If the drive machine runs at reduced speed, the voltage
or at above 2 kV on high-voltage machines (= 1 kV). regulator´s underspeed protection cuts in and de-excites
the machine. Irregular running will lead to deviations
Due to the capacitive charge in the winding, the from the nominal ratings.
measuring unit indicates the correct insulation resistance
value only after several seconds have elapsed. Earth the The machine is voltage-regulated and maintains a
winding immediately after the measuring voltage has voltage accurate to ± 1% in any condition between no
been switched off. load and full load, even if its speed fluctuates by ± 5%.
If the insulation values are too low, first check the In the case of special versions, the order values
terminal insulation for dirt and moisture. Clean or dry confirmed by the manufacturer should be adopted.
them as the case may be, and repeat the measurement.
1.12.3. No-load operation
Damp windings can lead to current leakage, flash-over
or breakdown. The no-load voltage can be adjusted within a range of
UN ± 8% by connecting the voltage setting rheostat to
If insulation resistance on new, cleaned or repaired terminals s and t.
windings is less than that stated below, drying out is
needed (see Item 1.18, Drying out the machine). The voltage regulator ensures that the voltage remains
constant as the machine warms up to its normal
On low-voltage machines with a nominal voltage below operating temperature.
1 kV, and in the rotor winding, insulation resistance
should not be less than 5 MO at a winding temperature 1.12.4. Parallel operation
of 25°C.
Machines operated in parallel are equipped with a
In the case of medium- and high-voltage machines with damper cage. They can be operated with identical or
a nominal voltage equal to or greater than 1 kV, the dissimilar machines or if necessary in parallel with the
insulation resistance in MO must be calculated using the mains.
following formula:
R = 3 + 2 x UN The three familiar preconditions for parallel operation

must be complied with:
Where UN is the nominal voltage of the machine
expressed in kV. • Identical voltages
• Identical frequencies
When testing insulation and measuring the windings, • Identical phase angles
these must be connected to the posts or bars as the case
may be, so that these parts are tested as well. Matching can be carried out manually or by an
automatic synchronizing device. For further details, see
Secondary connections such as measuring connections the supplier´s technical description.
to transformers and all connections to regulating,
protection or interference suppression circuits, must be In parallel operation, a distinction must be made
tested separately. Each of these connections must be between active and reactive load distribution.
checked individually at the terminal strip. This also
register the insulation resistance of the terminal strip. Active load distribution depends only on the speed
characteristic of the drive and cannot be influenced by
the electrical machine itself.

Rev. November 2001
Reactive load distribution is determined by the electrical
machine´s voltage characteristic, according to load. If there is moisture or dust in the terminal box, it must be
removed from the surface of the insulating parts. The
1.12.5. Loss of remanence reason for the accumulation of moisture or dust must
then be established and rectified.
If the auxiliary exciter machine (G3) has lost its
remanence, that is to say there is no voltage at terminals If severe dust occurs, the electrical machine should be
UH1-UH2 and WH1-WH2, terminal I2 (+) and K2 (-) blown through at regular intervals with dry compressed
must be excited briefly with a DC voltage (1,5 – 12 Volt) air, as it is running down to a standstill.
while the machine is running.
Clean the machine´s surface regularly as well, to prevent
dust and dirt from bulding up and adversely affecting the
1.13. Power factor regulation dissipation of heat.
For operation in parallel with the mains the machine can Make sure that the air inlets and outlets are not
be equipped with an additional automatic power-factor obstructed during operation.
regulator (for preset co phi range, see test report). For
further details, refer to the description and adjustment Apart from the bearings the dust filters (if installed) and
instructions for the additional „Cos“ power-factor the attached cooler, the machine requires no routine
regulating module in conjunction with the „COSIMAT N“ maintenance.
voltage regulator.
If carbon brushes are installed on the machine in
1.14. Interference suppression equipment designed to perform various monitoring
functions, they must be checked for wear at regular
The machine comply with radio inteference requirement intervals.
„N“ as stated in German VDE 0875. Note that the
standard of interference suppression is related to the If the machine has add-on equipment, for example a
quality of earthing. cooler, the additional maintenace instructions issued by
the manufacturers of this equipment must be complied
Disconnect suppressor capacitors, measuring with.
transfomers and regulators during high-voltage
insulation tests or if insulation measuring equipment is in Like any other machine, the electrical machine requires
use (if the test voltage reaches 80% of the factory´s test to be treated with care.
voltage).
1.17. Bearings
1.15. Operation 1.17.1. Ball and roller bearings
During operation, current-conducting and rotating parts The machine is fitted with anti-friction bearings. The DS
must be sealed with the covers provided for this purpose. has a floating bearing, the NDS a fixed bearing.
Increased vibration may result from insufficiently assurate If the bearings on either side are of the deep groove ball
alignment, poorly fitted foundations or frame, or weak bearing type, they are pre-loaded in relation to each
mountings. In addition, vibration can be introduced from other by spring elements, this ensures smoother running
the drive and non-drive sides. and reduces the negative effects of external sources of
vibration on the bearings. Deep-groove ball bearings are
1.16. Maintenance installed at both bearing points only to special order.
Before starting work on the machine make sure that it is The standard bearing specification is as follows: on the
switched off and take action to prevent it from being drive side, a roller bearing, on the non-drive side, a ball
switched on again. bearing or a duplex bearing consisting of one roller
bearing an one ball bearing.
Ensure that machine components which are live during
operation are at zero voltage (by earthing or Each of the machine´s bearings is normally provided
disconnecting the wiring). with a relubricating device. If a duplex NDS bearing is
installed, note that there are two grease nipples for
All work must be performed by qualified staff possessing relubricating. Refer to the appropriate column in the
the necessary knowledge and experience.

Rev. November 2001
lubrication chart for the correct volume of grease per Lubrication chart
nipple.
Type Lubrication Relubrication intervals in hours
Regreasing should be carried out with a grease gun at points* for machine running speed of:
the nippples provided on the machine. Quantity in
g
A regulator is installed to control grease volume, so that
1000-1200
1500-1800
old grease is expelled from the bearing.
500-600
750-900
bearing
bearing
Double
Single
Before regreasing, clean the nipple so that dirt cannot
min-1
min-1
min-1
min-1
DIG
enter the bearings.
120/
Where possible, apply grease when the machine is
… 60 40 2500 2000 1500 1000
running at reduced speed, unless this represents a
121
hazard for the operating personnel.
130/
… 80 60 2500 1500 1200 800
• Relubricating the bearings
131
140/
Ball and roller bearings are supplied ex- factory pakked
with high-quality anti-friction bearing grease and are … 100 60 2000 1500 800 600
therefore ready for immediate operation. Machines with 141
relubricating devices bear a plate on which the following 150/
information is stated: … 100 60 2000 1000 800 600
151
Relubricating interval in hours of operation
Quantity of grease 156 100 60 1800 900 700 500
Type of anti-friction bearing grease * In the case of double bearing, the amount of grease
stated in the „double bearing“ column is to be injected
• Regreasing interval into each of the grease nipples.
Bearing must be relubricated regularly in accordance

with the specified relubricating intervals (see chart). • Ball and roller bearing greases
Machines which have not been run for very many hours On delivery, the bearings are lubricated with high-grade,
must be relubricated at least once a year. If the stated lithium-saponified grease of Grade 3 consistency )NLGI
relubricating interval is below 1,200 hours, relubricate classification). The factory uses Shell Alvania R3 for this
twice a year. purpose.
Under adverse operating conditions, e.g. a humid The grease channels and the channel between the nipple
atmosphere, relatively high dirt accumulations, severe and bearings are filled with anti-friction bearing grease
vibrational loadings ets., the relubricating interval must before leaving the factory. The following alternative types
be reduced accordingly. If the permitted coolant of lithium-saponified anti-friction bearing grease may be
temperature is exceeded by app. 15°C, the relubricating used:
interval must be halved.
Shell Alvania R3
• Relubricating quantity Arcanol L71
Alpha lub LGMT 3
The machine´s bearings must each be relubricated with
the amount of grease stated. Remove expelled grease Or a lithium-saponified brand-name grease of
from the bearing points. equivalent specification, heat-resistant up to at least
When relubricating the bearings, run the machine if 130°C and complying with German Industrial Standard
possible at half speed for one hour to distribute the DIN 51825.
grease effectively. During this period, check the
temperatures of the bearings and compare them with the Recommendation:
temperatures recorded before relubricating.
Always relubricate the bearings with the same selected
brand of grease.

Rev. November 2001
• Dismantling the bearings
Once they have cooled down, pack the bearings fully
During shaft production, the bearing seat and the with grease. The inner and outer bearing covers must
bearing stop shoulder on the shaft are subject to each be filled with grese to approx. 50% of their full
particularly stringent quality control. This is essential to capacity.
maintain the accuracy of shape needed to keep the
bearings fully operational. When dismantling the • Monitoring the bearings
bearings, it is therefore important to handle the bearings
and bearing rings with particular care, otherwise the The first indication of damaged bearings is usually a
bearing seats on the shaft and bearing plate could noticeable change in temperature or running behavior,
become damaged. or noise and vibration if bearing damage has reached
and advanced stage.
To simplify dismantling, the parts can be heated
uniformly all round to a temperature of app. 80°C. Do Recommendation:
not install bearings previously removed, but renew them.
Monitor the bearings by measuring transmitted noise and
• Assembling the bearings vibration at regular intervals, and compare the readings
with those taken on previous occasions.
Bearings must only be renewed by a qualified person
possessing the necessary knowledge and experiece,
working in a dust-free environment, on a clean surface 1.18. Drying out the machine
and using suitable tools including metric wrenches.
The grease and bearings must be kept free of impurities, To protect the machine against moisture, the built-in
otherwise they will wear out faster and possibly even fail. heating should always be switched on when the machine
The correct arrangement of the bearing components does not emit any heat of its own. Even a slight increase
must be retained, this applies particularly in the event of in the temperature of the air inside the machine will
repair work. prevent moisture condensation on the insulating
components.
When renewing bearings, install original type-approved If the machine´s insulation value drops below that stated
bearings only, and maintain the corect amount of in the chapter „Insulation resistance“, the machine must
bearing play. The grease regulating disk should be be dried out.
rigidly attached to the shaft. Do not remove new
bearings from their packs until just before they are In many cases it can be dried suitably using its own
installed. Do not wash the bearings out, as the ventilation system, but it should not be electrically live
anticorrosion agent applied to them is compatible with while this is being carried out. De-excite the machine as
most customary anti-friction beraing greases. indicated in its circuit diagram. Operate the built-in
Clean the parts of the bearing that are to be re-installed. heating when drying out with the machine´s own
Before fitting the bearing, check for dimensional ventilation system.
accuracy and lack of distortion at the bearing seats on
the shaft and in the housing. If no improvement in the insulation resistance is
registered after a running period of approx. 2 hours,
When single-piece bearings (e.g. deep-groove ball the machine must be dried out additionally with dried
bearings) are installed, the force exerted to fit them must air supplied from the outside.
always be applied to the firmly located race, which has If this in turn does not increase the insulation resistance
to be mounted first. Forces applied to the free-moving after approx. 4 hours, the machine must be dried out by
race have to be transmitted through the balls or rollers, passing an electric current through the stator and rotor
which can damage them and their tracks. windings.
Installation of separable bearings (e.g. roller bearings) is However, this taks requires special knowledge and must
more straightforward. The two races can be installed therefore only be performed by personnel that has
separately. A screwing movement when assembling them received specific training. Please contact our service
helps to avoid rub marks. organization in this case.
When fitting the bearing on the shaft, heat it to about For additional information on bearing renewal or special
80°C in an oilbath, oven or by a suitable inductive operating conditions such as run-up synchronization,
heating method. Make absolutely sure that it is located rapid excitation or de-excitation, please do not hesitate
centrally and in positive contact with the shaft shoulder. to contact our engineers.

Rev. November 2001
Bunsenstraße 17
Phone: +49(0)841-792-0
Fax: +49(0)841-792-250

Dreieich branch
Benzstraße 47-49
Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40
Enclosure to Operating Instructions
Advise for Commissioning
Generator with vibration
absorbers on foundation
The relative movements between the gen-set and

By connection of the cables it must be ensured that
the foundation have to be compensated for by a
no forces have an effect on the machine connection
sufficiently long free cable length between the cable
terminals. The same counts for the time during
fixing on the gen-set and the foundation.
assembly.
If shock load or vibrations are to be expected, the

cables should be fixed over the cable clips and the
cable platform.
By elastic mounted gen-sets (see picture above)

sufficient 'free cable length' should be ensured to
compensate the movements of the diesel/gas motor.
In order to ensure that the movements do not have
a negative influence on the connection terminals,
the cable must be fixed with max. 300 mm distance
from the terminal box screw fitting. This cable fixing
has to be connected rigidly to the gen-set in order
to avoid relative movements between the cable
fixing and the terminal box.
AnB / e / 20-10-2003 / B Page 2

Generator with vibration
absorbers on frame base
By connection of the cables it must be ensured that In order to ensure that the movements do not have
no forces have an effect on the machine connection a negative influence on the connection terminals,
terminals. The same counts for the time during the cable must be fixed with max. 300 mm distance
assembly. from the terminal box screw fitting. This cable fixing
has to be connected rigidly to the gen-set in order
If shock load or vibrations are to be expected, the to avoid relative movements between the cable
cables should be fixed over the cable clips and the fixing and the terminal box.
cable platform.
The relative movements between the gen-set and
By elastic mounted gen-sets (see picture above) the foundation have to be compensated for by a
sufficient 'free cable length' should be ensured to sufficiently long free cable length between the cable
compensate the movements of the diesel/gas motor. fixing on the gen-set and the foundation.
AnB / e / 20-10-2003 / B Page 3

Connections
Using the Protection switches Q1, F1, F2

Cable connection acc. to DIN 46200
The purpose of these switches is to protect the
voltage transformers T24 (Q1) and the auxiliary
Elastic parts, such as spring washers, can be used
exciter winding (F1, F2). In case of failure, these
in the electrical connection, however, only on one
switches will lead to a quick de-excitation of the
side of the clamped conductor. If necessary,
machine.
additional washers are to be used. The other side is
for current conduction, why only washers or security
These switches are not to be used for de-exciting
locking plates of copper-zinc-alloys must be used.
the machine during operation or maintenance!
By electrical connection with eyelet rings, the eyelets
have to be protected by washers on both sides
Open star point
against bending.
The voltage transformer T24 has to be disconnected
and the cables sufficiently insulated! De-excite the
De- excitation
machine as described above.
Open the bridges UH1-24 and WH1-14 on the No tests are to be performed with open star point!
terminal strip X2. De-excitation with extern switch The correct connection of the power cables can be
takes place on these terminals, too. checked with appropriate equipment.
AnB / e / 20-10-2003 / B Page 4

Maintenance for earthing brush
All brushes and holders must be checked for free

Optimum maintenance and care for earthing movement. Blocked brushes may lead to damage.
brushes is the base for smallest brush wear. The
maintenance of brushes must take place after Worn out brushes must be renewed in time, so that
certain intervals that depend on the alternators size damages at the contact surface on the shaft can be
as well as load and ambient conditions. avoided. New earthing brushes do not need grind-
in (other than slip rings).
Brushes are subject to wear and tear and must be
cleaned by air (pressure or suction) from time to Using brushes bigger than the original size is only
time. Routine check every 3 months is possible after agreement with the supplier.
recommended by AvK to ensure about operational
behaviour and suitable changing intervals.
AnB / e / 20-10-2003 / B Page 5

Maintenance of Earthing Fault
Monitoring
Optimum maintenance and care of ht e brushes Note:

and slip rings is the base for smallest wear. The
maintenance must take place in certain time The Earthing Fault Monitoring is mounted on the
intervals. The frequency of the maintenances NDE of the machine.
depends on alternator size as well as on load and
ambient conditions. Attention:
Maintenance works must be performed only during

Brushes are subject to wear and tear and must be
standstill of the machine.
cleaned by air (pressure or suction) from time to
time. Routine checks every 3 months is
recommended by AvK in order to estimate the
necessary time intervals during the actual operation
Electrical Machines with two shaft
conditions.
ends
All brushes and holders must be checked for free
Bearing currents by electrical machines with two
movement. Blocked brushes may lead to damage.
shaft ends must be avoided.
Worned out brushes must be replaced in time in
AvK recommends an insulated coupling mounted
order to avoid damages on the slip rings and to
on the NDE.
ensure the perfect function of the Earthing Fault
Monitoring. New brushes need grind-in with the
Another possibility is that all bearings of the NDE
slip rings. The use of larger brushes than originally
aggregate are insulated.
mounted is only possible after agreement with the
supplier.
AnB / e / 20-10-2003 / B Page 6

Anti - condensation heater:
The anti condensation heater is to be connected

according to correct rating and supply voltage.
Please refer to rating plate of the machine.
Control of the anti – condensation heater should be

done that the heater
- is switched on after the machine has stopped,

- is switched off before starting up the machine.
Tubular heater type RHK T + H art. no.

100870 and 100872
Description
2 heaters type RHK dia. 8, 5mm x 500mm long

assembled into two brackets made of stainless steel
as per our drawing no 31522, heaters wired in
parallel by brass brackets, silicon insulated
connection cable 3000mm long.
Number of heater elements is according to required
heating power.
Technical data of the heaters
Heater sheath: Chrome-Nickel-Steel AISI 321
Heater wire: NiCr 8020, Mat. no.: 2.48869
Insulation material:
pure magnesium oxide, highly compacted
Connection:
threaded bolt M4 with silicon insulated cable
Tolerances
Diameter of heaters: 8,5mm ± 0,15mm

Straight length of
heaters: 500 ± 2 %
Wattage per heater: 500 Watt ± 10 %
Total wattage (4 heaters):1000 Watt ± 10 %
Voltage: 230 Volt
Dielectric strength: 1250 V
Final test: per standard
DIN EN 60 335
AnB / e / 20-10-2003 / B Page 7

AnB / e / 20-10-2003 / B Page 8
Bolting torque for fixing screws
If no further indications are made , use the

following bolting torque for connections of fixing
screws and fixing nuts:
screws screws
property class property class
8.8 4.6
M4 3,0 1,1
M5 3,5 2,2
M6 9,0 3,7
M8 18 9,0
M10 45 18
M12 50 31
M16 110 75
M20 250 150
M24 440 255
M30 980 510
M36 1730 890
M42 2700 1450
starting torque in Nm
Values according to VDI 2230 calculated

considering the maximal admissible surface
pressure under the screw head and a frictional co –
efficient µ ges = 0,125
AnB / e / 20-10-2003 / B Page 9

Dust filter made of metal fabric
Description
Design of the filter
The frames and the plates of the filter are fabricated

of:
• Constructional steel with zinc coated mesh wire
• Stainless steel with stainless steel mesh wire
alternatively depending on application
conditions
Type of filter
B1 according to DIN 24185 / part 100

EU2 according to DIN 24185 / part 2
Medium degree of deposition 65 = 80 %
Maintenance
The maintenance intervals depend on the local dust

accumulation. The dust protective filter plates have
to be cleaned with the usual commercial detergents.
Cleaning with high-pressure cleaning devices is
also possible.
Caution:
Do not wet the filter plates with oil!

Observe the instructions for pollution
control.
The following detergents can be used when

cleaning mechanically:
Calgonit / Somat / Topmat 760 (or equivalent)
If only a manual cleaning is possible, use the

following detergents:
Rivonit / RG 1083 (or equivalent)
Regular checks and cleaning of the dust

protective filter system is indispensable for
the safety in operation of the electrical
machines
AnB / e / 20-10-2003 / B Page 10

AnB / e / 20-10-2003 / B Page 11
Bunsenstraße 17
Phone: +49(0)841-792-0
Fax: +49(0)841-792-250

Dreieich branch
Benzstraße 47-49
Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40
AnB / e / 20-10-2003 / B Page 12
Regulator Descriptions
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
 Copyright 2002 ABB. All rights reserved.
UNITROL 1000-15
User’s Manual
Automatic Voltage Regulator

Compact voltage regulator for synchronous
machines up to 15 A exciter current.
Revision
Control: 4.3xx
Panel: 4.3xx
CMT1000: 4.3xx
Prep. Peter Moor 2006-06-07 User’s Manual No. of p.
Appr.
Sami Karttunen 2006-06-07 UNITROL® 1000-15 99
Resp.
dept. ATPE
Document number Lang. Rev. ind. Page
ABB Switzerland Ltd 3BHS201795 E80 en C 1

Important Notice
Our experience has shown that, if the information and recommendations contained in this Operating
Instructions are observed, the best possible reliability of our products is assured.
The data contained herein purports solely to describe the product and is not a warranty of
performance or characteristics. It is with the best interests of our customers in mind that we
constantly strive to improve our products and keep them abreast of advances in technology. This
may, however, lead to discrepancies between a product and its "Technical Description" or "
Operating Instructions".
This document has been carefully prepared and reviewed, however should in spite of this the reader
find an error, he is requested to inform us at his earliest convenience.
It is scarcely possible for the operating instructions for technical equipment to cover every
eventuality, which can occur in practice. We would therefore request you to notify us or our agent in
the case of all unusual behaviour that does not appear to be covered by these operating instructions.
It is pointed out that all local regulations must be observed when connecting and commissioning this
equipment in addition to these operating instructions.
We cannot accept any responsibility for damage incurred as a result of mishandling the equipment
regardless of whether particular reference is made in these operating instructions or not.
We lay particular stress on the fact that only genuine spare parts should be used for replacements.
All rights with respect to this document, including applications for patent and registration of other
industrial property rights, are reserved. Unauthorized use, in particular reproduction or making
available to third parties, is prohibited.
Manufacturer’s address
ABB Switzerland Ltd
Excitation Systems, Voltage Regulators
and Synchronizing Equipment
CH-5300 Turgi / Switzerland
Telephone: +41 58 589 24 86

Fax: +41 58 589 23 33
Email: pes@ch.abb.com
Internet: http://www.abb.com/unitrol
24 h - Hotline for urgent service inquiries: +41 844 845 845

Contents
1 SAFETY INSTRUCTIONS ................................................................................................ 5
1.1 General................................................................................................................................................5
1.2 Safety Instructions ...............................................................................................................................6
2 DEVICE DESCRIPTION ................................................................................................... 7
2.1 Introduction..........................................................................................................................................7
2.2 Area of application...............................................................................................................................8
2.3 Hardware .............................................................................................................................................9
2.3.1 Control elements and interfaces .......................................................................................................10
2.3.2 Overview of the device connections..................................................................................................11
2.3.3 Device connections ...........................................................................................................................12
2.3.4 Digital inputs ......................................................................................................................................15
2.3.5 Digital outputs....................................................................................................................................17
2.3.6 Analog inputs.....................................................................................................................................19
2.3.7 Analog outputs ..................................................................................................................................21
2.4 Software ............................................................................................................................................22
2.4.1 Operating modes ...............................................................................................................................22
2.4.2 Description of the parameters ...........................................................................................................26
3 INSTALLATION AND DISPOSAL .................................................................................. 37
3.1 Mechanical installation ......................................................................................................................37
3.2 Earthing and wiring............................................................................................................................37
3.3 Disposal.............................................................................................................................................37
4 OPERATION................................................................................................................... 39
4.1 Operation on the unit.........................................................................................................................39
4.1.1 Keypad ..............................................................................................................................................39
4.1.2 Display...............................................................................................................................................39
4.1.3 Example of parameter setting ...........................................................................................................40
4.1.4 Menu structure of display ..................................................................................................................41
4.1.5 Fault message on the display............................................................................................................47
4.2 PC-Software ......................................................................................................................................48
4.2.1 Operation using the software ............................................................................................................49
4.2.2 Example of parameter setting using CMT 1000................................................................................50
4.2.3 Menu structure of CMT 1000.............................................................................................................51
4.2.4 Save parameter file ...........................................................................................................................67
4.2.5 Evaluation of the waveform ...............................................................................................................68
4.2.6 Error message ...................................................................................................................................71
5 COMMISSIONING .......................................................................................................... 73
5.1 Safety regulations..............................................................................................................................73
5.2 Setting aids........................................................................................................................................74
5.3 Work carried out while machine is at a standstill ..............................................................................79
5.4 Work carried out while machine is running .......................................................................................79
6 MAINTENANCE AND FAULTS ...................................................................................... 83
6.1 Safety regulations..............................................................................................................................83
6.2 Maintenance ......................................................................................................................................83
6.3 Trouble shooting................................................................................................................................83
6.4 Repair ................................................................................................................................................87
7 APPENDIX...................................................................................................................... 89
7.1 General Data .....................................................................................................................................89
7.2 Settings record for UNITROL 1000-15..............................................................................................90
7.3 Parameter settings, default values ....................................................................................................91

This page is intentionally blank.

1 SAFETY INSTRUCTIONS
1.1 General
The safety instructions shall be followed during installation, commissioning, operation and
maintenance of the excitation system. Read all instructions carefully before operating the device and
keep this manual for future reference.
Required Qualification
Personnel involved in installation work and commissioning of the UNITROL 1000-15 must be familiar,
specially instructed and informed about the residual danger areas according to the regulations
currently in force.
Operating personnel is not permitted to work at the control system.
Specially instructed personnel must only carry out maintenance and repair work.
The maintenance personnel must be informed about the emergency shutdown measures and must
be capable of turning off the system in case of emergency.
The maintenance personnel must be familiar with the accident prevention measures at their
workplace and must be instructed in first aid and fire fighting.
Responsibilities
It is the owner’s responsibility to ensure that each person involved in the installation and
commissioning of the UNITROL 1000-15 has received the appropriate training or instructions and
has thoroughly read and clearly understood the safety instructions in this chapter.

1.2 Safety Instructions
The safety instructions always appear at the beginning of each chapter and/or precede any
instruction in the context where a potentially dangerous situation may appear. The safety instructions
are divided into five categories and emphasized by the use of the following layout and safety signs:
DANGER!
This symbol indicates an imminent danger resulting from mechanical

forces or high voltage. A non-observance leads to life-threatening
physical injury or death.
WARNING!
! This symbol indicates a dangerous situation. A non-observance may lead

to bad or life-threatening physical injury or death.
CAUTION!
This symbol indicates a dangerous situation. A non-observance may lead

to physical injury or cause damage to the converter.
NOTICE!
This symbol emphasizes important information. A non-observance may

cause damage to the converter or to objects close to it.
IMPORTANT!
This symbol indicates useful information. Not to be used to indicate

dangerous situations.

2 DEVICE DESCRIPTION
2.1 Introduction
UNITROL 1000-15 is an automatic voltage regulator of the latest design for synchronous generators
and synchronous motors. The unit contains the most advanced microprocessor technology together
with IGBT semiconductor technology (Insulated Gate Bipolar Transistor).
A practical and simple-to-operate panel on the unit is used for all control operations. In addition, user-
friendly software facilitates commissioning and allows optimisation of operation.
The mechanical construction is extremely compact and robust.
The UNITROL 1000-15 unit can be connected to a 40 A Power Module called UNITROL 1000-PM40.
For further information please refer to the separate User’s Manual.

2.2 Area of application
This advanced-design automatic voltage regulator is used for the excitation of indirectly excited
synchronous machines. This unit is only suitable for this one area of application.
The regulator can also be switched over to function as a reactive power-, power factor- or field
current regulator.
Back-up Channel
SM = Synchronous Machine
E = Exciter UNITROL 1000
R
UNITROL 1000
R
Batt.
PMG = Permanent-Magnet-Generator
Shunt excitation with:

- short circuit support (Boost)
Optional:
- Power System Stabilizer (PSS)
- Synchronization unit SM E
- Diode monitoring
- Change over to a back-up unit.
UNITROL 1000

R
Generator or motor excitation with

PMG or external supply.
PMG
SM E
UNITROL 1000

R
Replacement of voltage regulators for

generators or motors with direct-current
excitation machines.
SM =

2.3 Hardware
Structure:
The device is built into an aluminium casing with
cooling flanges.
The connection terminals are integrated into the
front of the circuit boards, which are arranged on
top of one another.
Power electronics:
The power part is fitted with an IGBT
semiconductor. The average value of the output
voltage is always positive. The output is current-
limited and thus short-circuit-proof.
Control elements:
The operating keys, the display and the sub-D
connector for the RS-232 interface are located on
the unit cover.
Installation:
Dimensions in mm The site of installation must be dry and free of
dust.
Rack mounting Wall mounting

100 mm

UNITROL 1000
R
Mounting:
The UNITROL 1000-15 is designed for rack or
100 mm wall mounting in upright position.
For optimal cooling is to keep free a distance
142 from approx. 100 mm around the unit.
Connection diagram:
Auxiliary supply UAUX for control electronics
Digital in- and outputs L1 L2 L3
(+) (-)
Analog in- and outputs
UN1000-15
~/=
Measurement
UNET
and control
=
inputs
UM
AVR RS-232
IM2 RS-485 or MODBUS
CAN Bus
PWM
Supply
power electronics
UPWR
Ie - (+) L1
SM EE (-) L2
L3
+

2.3.1 Control elements and interfaces
MAIN
Monitor
Mode = Auto Carrying out settings on the unit
Connected: 1
The four-line display and the four keys are
sufficient to allow complete operation.
All settings can be carried out directly on the
unit without additional equipment:
OK
• Configuration of inputs and outputs
• Parameter setting
ESC
• Display of important measuring values.
Interface with PC
UNITROL 1000R
Parameter setting and also optimisation is

possible using the user-friendly software
CMT1000 for Microsoft Windows.
Connection cable, sub-D, 9 pol (female)
• Configuration of inputs and outputs

• Parameter setting
• Trending function for optimisation of the
controller (Oscilloscope, Power chart)
• Display of important measuring values
• Parameter File upload or download.
Terminal block
serial port
DGND
DGND
+Vdig
+Vdig
+Vref
+AI 1
+AI 2
-Vref
-AI 1
-AI 2
DI 5
DI 6
DI 7
DI 8
32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47
I M2 485 CAN
AGND
DIO 1
DIO 2
DIO 3
DIO 4
+Vdig
+Vdig
AO 2
+Vref
+AI 3
AO 1
-Vref
-AI 3
gnd
S1 S2 - -
+
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 50 51 52 53 54 55
L1
UML2 L3 L1
U NET
L3 NC +
Ie - L1(+)
U PWR
L2(-) L3 L1(+)
U AUX
L2(-) L3
1 2 3 4 5 46 7 8 49 10 11 12
4 13 14 15
4
J2 J4
RS-485 CAN

2.3.2 Overview of the device connections
UN1000-15
(+10 V) +Vref L1(+) 13
(-10 V) -Vref 14
(+24 V) +Vdig L2(-) UAUX
L3 15
7 AGND
DGND
10 L1(+) + 8
11 L2 (-)
UPWR Ie
12 L3 - 9
+ 50
J2 485
1 L1
PID RS-485 120R
or
2 - 51
UM L2 MODBUS
3 52
L3
16 gnd 53
S1
CAN
IM2 17 S2 + 54 CAN
Bus
DSP J4
120R
4 L1 - 55
UNET
5 L3
6 (NC)
RS-232 9 pol serial port
32
33 +AI1
~ AO1 23
34 -AI1 # 24
AO2 AOUT
35 +Vref
AGND 25
AIN 36 +AI2 ~
37 -AI2
38 -Vref # in, norm.
39 +Vdig 26
DIO1 27
18 +Vref DIO2 28 DIN,
19 +AI3 ~ in, inv. +Vdig 29 DOUT
20 -AI3 out, inv. DIO3 30
AIN
21 -Vref # DIO4 31
22
out, norm.
40 DGND
41 +Vdig
42 DI5 norm.
43 DI6
DIN
44 +Vdig
45 DI7
46 DI8 inv.
47 DGND

2.3.3 Device connections
Terminal designation Signal Circuit

L1(+) = 13 Auxiliary supply UAUX UN1000-15
L2(-) = 14 External 3~
9 to 250 V~ L1,L2,L3
L3 = 15 - AC input voltage three-phase UN1000-15
(250 V / 140 V) or 1~
50 to 250 V~ L1,L2
- AC input voltage single-phase
UN1000-15
(250 V) or 2=
18 to 300 V= L1(+),L2(-)
- DC input voltage
L1(+) = 10 Power electronics supply UPWR UN1000-15
L2(-) = 11 - AC input voltage three-phase, External 3~
0 to 250 V~ L1,L2,L3
L3 = 12 UN1000-15
AC input voltage single-phase 0 to 250 V~
1~
L1,L2
and excitation current < 10 A
UN1000-15
or 2=
- DC input voltage 0 to 300 V= L1(+),L2(-)
- AC input voltage single-phase External UN1000-15

and excitation current >10 A
L1
Rectifier: 35 A, 1200 V 0 to 250 V~
Capacitor: 1000 µF, 600 V L2
Three-phase: Measurements inputs External
UN1000-15
L1 = 1, L2 = 2, L3 = 3 Three-phase: L1
L2 UM
S1 = 16, S2 = 17 - Machine voltage UM L3
max. 250 V / 0.2 VA
Single-phase: SM
L1 = 1, L3 = 3
S1 = 16, S2 = 17 Single-phase: S1
IM2 1 A / 0.1 VA
- Machine current IM2 S2
External
or L1
UN1000-15
Single-phase: L3 UM
max. 150 V / 0.2 VA
- Machine voltage UM
or External
UN1000-15
Three-phase with ground L1
L2 UM
(Three ph gnd) L3
max. 150 V / 0.2 VA
- Machine voltage UM L1 L2 L3
L1 = 4, L3 = 5 Single-phase: External
UN1000-15
Line voltage measurement L1
L3 UNET
UNET max. 150 V / 0.2 VA
+ =8 Excitation current output Ie UN 1000-15 External
- =9 +
0 to 300 V=
15 A = E
-
Earth connection = 7 Earth connection

DIO1 = 27 Digital inputs
DIO2 = 28 DIO1 to DIO4 External 24 V DC UN1000-15
DIO3 = 30 +Vdig
DIO4 = 31 DIO1 to DIO4 can be
+Vdig = 26, 29 operated either as inputs or 24 mA
in
outputs. DIO
1k
out
Digital outputs
DIO1 to DIO4 UN1000-15 External
24 V DC
+Vdig
Caution:
in
Configured as outputs, DIO1
to DIO4 must not be DIO
connected directly with +Vdig
(causes short circuit via
internal transistor) out
DI5 = 42 Digital inputs

DI6 = 43 DI5 to DI8 External 24 V DC UN1000-15
DI7 = 45 +Vdig
DI8 = 46 Controlled from potential-free
24 mA
+Vdig = 41, 44 contacts
DI
DGND = 40, 47
1k
The internal 24 V supply may be loaded with a maximum of 300 mA by all used digital inputs
and outputs.

+AI1 = 33, -AI1 = 34 Analog inputs External 10 V DC UN1000-15
+AI2 = 36, -AI2 = 37 AI1 to AI3 +Vref
4.7k
+AI3 = 19, -AI3 = 20 +AI 100k
+
+Vref = 18, 35 R = 10 k , 1 W R 47k
-AI
-Vref = 21, 38 -
100k
AGND = 25 AGND 47k
Earth = 22,32,39 4.7k
AGND
-Vref
-10 V DC
External
UN1000-15
max. ±10 V
+AI + 100k
+
47k
-AI -
-
100k
47k
+AI1 = 33, -AI1 = 34 Analog inputs digitally UN1000-15

+AI2 = 36, -AI2 = 37 assigned 10 V DC
+AI3 = 19, -AI3 = 20 AI1 to AI3 +Vref
+Vref = 18, 35 (DI9 to DI14) +AI

4.7k
100k
-Vref = 21, 38 see chapter 2.3.6 + Ain
47k
+Vdig = 26, 29, 41, 44 -AI
-
AGND = 25 100k
DGND = 40, 47 47k
Earth = 22,32,39
AO1 = 23 Analog outputs UN1000-15 External
AO2 = 24 AO1 to AO2 max. ±10 V
max. ±20 mA
AGND = 25 - ±12 V 100R
AO
+
AGND
Serial port: Sub-D, 9 pol, Serial interface RS-232 Standard cable

Male RX =2 (terminals 2 and 3 crossed)
TX =3 2 2
GND = 5 3 3
5 5
485: + = 50, - = 51 - Serial interface RS-485
MODBUS - or MODBUS
CAN: += 54, - = 55 CAN Bus for Power

UNITROL 1000-15 Power Module
gnd = 53 Module X102
UNITROL 1000-PM40 gnd
53 1
CAN_GND
- 55 2
Shielded cable: 120R
CAN_L
2x 2x 0.34 mm2, 52 3
CAN_SHIELD
Impedance 120 ,
J4
+ 54 4
CAN_H
5
CAN_POWER
Length of cable < 30 m
Earth: = 52

2.3.4 Digital inputs
Input function Description

None Input not assigned
Excitation ON active Excitation ON demand active:
- Field flashing begins if Off Level > 0%
- Soft start begins after the Off Level has been reached (Auto mode)
Excitation ON not active Excitation ON demand not active: Mode Preset value
All setpoints are immediately set to Manual 0%
the following values and remain Open Loop 0%
fixed there. PF 1.0
Var 0%
Auto 100%
Gen CB Closed Status Circuit-breaker closed status active:
active - Activates current measurement
- This message triggers immediately the ramp of the soft start as if still
the hold time
Gen CB Closed Status Circuit-breaker closed status Mode Final value

no longer active changes from active to not active: Manual 90% Ie No Load
All setpoints are immediately set to Open Loop 90% 1/Kceil
the following values. Auto 100%
Parallel with Grid Status Parallel with grid status active:
- Enables together with Gen CB Closed possibility to change over to PF
and Var modes.
- Disables VDC mode.
Increase Increase setpoint of active regulator
Decrease Decrease setpoint of active regulator
Reset Setpoint Status reset setpoint is active: Mode Final value
The setpoint of the active regulator Manual Ie No Load
goes to the following value at ramp Open Loop 100% 1/Kceil
speed. PF 1.0
Var 0%
Auto 100%
Remote SP Enable Control signal for remote setpoint setting. The setpoints are controlled
by analog inputs.
PF Enable Power factor regulation active
Var Enable Reactive power regulation active
Manual Enable Manual active, field current regulation
Open Loop Enable Open loop, direct control of power transistor active
Synchronize Synchronize demand active
VDC Enable Voltage droop compensation control active
Secondary Net Net 2 on island operation (VDC)

Reset Alarm Clear the following alarms:
- System OK (not available)
- SW Alarm
Standby Standby demand active:
- The output of the AVR is turned off
- Boost is disabled
- Field flashing is off
- Integrator is kept in 1/Kceiling
- All limits are disabled
- There will be no data transmission to the RS-485 bus
- Mode is standby
- All setpoints are following the corresponding actual value
RC Fieldbus Block Disable the Fieldbus communication in local operation
FCB closed Status Field circuit breaker closed status active
The assignment of the digital inputs to the terminals DIO1 to 4, DI5 to 8, (DI9 to 14) can be selected
freely.
Polarity of the digital input

Software setting
24 V DC 24 V DC
inverted
DIO1 to 4 DIO1 to 4
DI5 to 8 DI5 to 8
normal DI9 to 14 DI9 to 14

2.3.5 Digital outputs
Output function Description

None Output not assigned
Boost Status signal boost is active
Boost supports excitation in the event of line short circuit or heavy load.
The boost function is blocked during field flashing and soft start.
Field Flashing Field flashing (voltage built up) active, if Excitation ON
See section 2.2.2 The next field flashing can only be started after Excitation ON or after
the power has been switched off.
During field flashing the output of the regulator is blocked in all
operation modes.
System OK (optional) In preparation
Limit Active One of the limiters (V/Hz, Ie, PQ or UM) is active
or setpoint limit has been reached (min. - or max. position)
V/Hz Limit Active V/Hz limiter active
SP Limit Reached Setpoint limit has been reached
SP Minimum Reached Minimum setpoint has been reached
SP Maximum Reached Maximum setpoint has been reached
Operational Limit Active Ie, PQ, UM limiter or Diode Alarm active
Min Ie Active Ie minimum current limiter active
Max Ie Active Ie maximum current limiter active
Min PQ Active PQ limiter active
Min UM Active Limit value for minimum machine voltage is fallen below,
voltage limiter active
Max UM Active Limit value for maximum machine voltage is exceeded,
voltage limiter active
Voltage Relay Active = machine voltage below boost threshold
Inactive = boost threshold and hysteresis exceeded
Not dependent on signal Excitation ON.
Close CB Command The command is released:
(Option) - Angle is in a value where it would take the Total CB Closing Time for
the breaker to close at zero degrees with current speed and
acceleration.
- Sync Check demand active
- The command is so long active as the command Sync Check is active
Sync Check Sync Check demand active:
(Option) - Generator circuit breaker is open
- Machine voltage is more than 50%
- Synchronization is possible (unit with Sync-Option)
- Synchronize is enabled
- Slip is between minimum slip and maximum slip
- Machine voltage is deviating from network voltage maximum Delta U
- Angle is between -maximum delta angle and +maximum delta angle

SW Alarm Software program process is out of order
Diode Alarm (Option) Event of open diode
Diode Trip (Option) Event of a shorted diode
SW Alarm or Diode Trip (Option) SW alarm and event of a shorted diode
MODBUS Com Alarm Loss of MODBUS command
Close FCB Command Command to close the field circuit breaker
Open FCB Command Command to open the field circuit breaker
The assignment of the digital outputs to the 4 terminals DIO1 to 4 can be selected freely.

2.3.6 Analog inputs

None Input not assigned
Auto Remote Setpoint External setpoint input to Auto regulator
PF Remote Setpoint External setpoint input to PF regulator
Var Remote Setpoint External setpoint input to Var regulator
Manual Remote Setpoint External setpoint input to Manual regulator
Open Loop Remote SP External setpoint input to open loop
UM Aux Auxiliary supply to the summing point of Auto regulator
Reserved2 Reserved for later function expansion
Cooling Media Temperature Input temperature measurement for the temperature influence limiter
Reserved4 to 5 Reserved for later function expansion
Digital Input 9(+) & 10(-) Assign digital inputs
The assignment of the analog inputs to the 3 terminals AI1 to 3 can be selected freely.
Level of the analog inputs, see parameter settings chapter 7.3

Internal signal value [%]
• External setpoint input
Setpoint max
Setpoint min
Ext. Setpoint Auto
-10 10 [V]
Uin0% Uin100%
UM Aux [%]
• Input to the summing point 10
max
Uin0% Analog in
-10 10 [V]
min Uin100%
-10
• Input voltage of the cooling media temperature

- Range: Uin0% = -10.0 V refers to -100 °C
Uin100% = 10.0 V refers to 100 °C

• Analog inputs digitally assigned
Two digital inputs can be generated from one analog input. See this example.
Voltage between the input (+)AI1 – (-)AI1 <= -5 V (+)AI1 – (-)AI1 >= 5 V
terminals
Uin Uin
0V +AI1 10V +AI1
Principle hardware configuration Ain Ain
10V -AI1 0V -AI1
DI9 = 1
-5.0 -2.0 DI9 = 0

Condition of the digital inputs DI10 = 0 Uin
2.0 5.0 [V]
DI10 = 1
Status of the digital inputs -> Din9(+) = 0 -> Din9(+) = 1

-> Din10(-) = 1 -> Din10(-) = 0
+AI or -AI shall not be active simultaneously.
Configuration of the inputs signals with the CMT-Tool:
Select the analog input AI1 and adjust Select the two digital signals
the input range DI9 from +AI
[Setup \ Analog Inputs] DI10 from –AI
[Setup \ Digital I/Os]
Direction = In Direction = In
None None
Auto Remote Setpoint Excitation ON
PF Remote Setpoint Gen CB Closed Status
Var Remote Setpoint Parallel with Grid Status
Manual Remote Setpoint Increase
Decrease
Open Loop Remote Setpoint
Reset Setpoint
UM Aux Remote SP Enable
Reserved2 PF Enable
Cooling Media Temperature Var Enable
Reserved4 Manual Enable
Reserved5 Open Loop Enable
Digital Input 9(+) & 10(-) Synchronize
Digital Input 11(+) & 12(-) VDC Enable
Digital Input 13(+) & 14(-) Secondary Net
Reset Alarm
Standby
- Range: Uin0% = 2.0 V RC Fieldbus Block
Uin100% = 5.0 V FCB closed Status

2.3.7 Analog outputs

None Output not assigned
Excitation Current Excitation current
PWM Pulse width modulation, control value is limited to minimum of 2%
Fbias Analog continuous signal presenting difference between UNET and UM
Fbias = fNET – fNOM – (Slipmax – Slipmin)/2
Output signal Fbias is forced to zero:
- Not in Sync mode
- Synchronization function not enabled (unit without Sync-Option)
- Network frequency is not between 45 to 66 Hz
The assignment of the analog outputs to the 2 terminals AO1 to 2 can be selected freely.
Level of the analog outputs, see parameter settings chapter 7.3
• Excitation Current Aout [V]

10
Caution: Ie0% must be less than Uout 100%
Ie100%
Uout 0%
Ie
400 [%]
-10
Ie 0% Ie100%
Aout [V]
• Fbias 10
Uout 100%
Uout 0% Fbias
-10 10 [Hz]
Fbias0% Fbias100%
-10
• PWM Output Aout [V]

10
Uout 100%
Uout 0% PWM
100 [%]
-10
The full voltage range runs from –10 V to 10 V at a resolution of 10 bits.

2.4 Software
2.4.1 Operating modes

Bump less changeover between all modes of operation
Automatic voltage regulation (Auto) UN 1000-15

Regulates the terminal voltage of the synchronous PID Regulator
machine.
Note: Current measurement for compensation / droop

SM E
UN 1000-15
Manual control
Regulates the field current of the excitation machine. PI Regulator
Note: No limiters will be active.
SM E
UN 1000-15
PID Regulator
PF or Var regulation (PF, Var)
Regulates the power factor or reactive power of the PF
synchronous machine. MVar
SM E
UN 1000-15
Open loop
Manual control with a fixed output signal.
Note: No limiters will be active.
SM E
Setting of operating modes see chapter 5.2, Setting aids

Voltage droop compensation control and reactive power allocation (VDC)
- For island operation only -
In order to share equally the amount of reactive power between parallel connected generators
UNITROL 1000-15 offers a special feature, called voltage droop compensation control. Units are
connected together with RS-485 bus.
In VDC mode, actually, all AVRs operate in Auto mode with voltage droop. However, each AVR (with
its own ID number) writes the value of its own amount of reactive power to the RS-485 bus. Each unit
reads these values and calculates a common average Mvar setpoint, and compensates the effect of
voltage droop. Therefore, voltage level on the busbar is always kept at 100% (not adjustable).
Load A Load B
RS-485
AVR 1 AVR 2 AVR 3 AVR 4

SM SM SM SM
Primary Net = 1
Primary Net = 1
Secondary Net = 2
Connections RS-485:
J2 J2
J2 + AVR 1 AVR 2 AVR 3 AVR 4
J2
120R 50 1 RS-485 1 50 1 RS-485 1 50 1 RS-485 1 50 + 120R
- 51 2 2 51 2 2 51 2 2 51 -
52 52 52 52
Cable cross-section = 2 x 0.75mm2

Cable impedance = 100 to 120R
Shielded twisted pair
When operating in VDC mode, the network can be divided to smaller entities. Each generator can
operate in two pre-determined island grids, called Primary Net and Secondary Net.
Secondary net is selected by means of a digital input. If this input is not active, primary net is
selected. Each net (island grid) shall have its own network number.

Synchronization (Sync)
The automatic synchronization of a synchronous machine with the line is achieved using the optional
integrated synchronizing function. By setting few simple parameters, UNITROL 1000-15 supplies the
corresponding control signals for the speed governor and closes the circuit breaker.
Analogue speed correction Fbias is given out from UNITROL 1000-15 analogue output, to speed
governor control summing point (not as pulse). This signal represents the difference of network
NOMINAL and network ACTUAL frequency. The reference (setpoint) value for the speed governor
must be nominal (50 or 60 Hz) and the Fbias given by UNITROL 1000-15 will drive the speed close
to actual network frequency.
Note that the speed control is not with INC/DEC pulses, and that is not possible to derive such pulses
from the Fbias signal. Also, the configuration possibilities of PT’s (machine/net) are very limited. See
chapter 2.4.2. Other functions, like dead bus synchronising, etc. are also missing. The circuit breaker
closing command is traditional type with no specialities (for one breaker).
CAUTION!
Power circuit breaker (CB) may only be closed if both voltages are at
least approximately synchronous (coincident).
Otherwise, faults in line operation, loading of the synchronous machine

and, in extreme cases, damage to the synchronous machine can result.
A separate synchrocheck relay must be used to secure the right

operation. For further information please contact ABB.
Measuring:
The values are formed from the two
measurement signals UNET and UM
UNET UN 1000-15
- Voltage difference (amplitude) Synchrocheck
Setpoint fSP = fNom
- Slip (frequency difference) CB
Command
- Phase-angle difference Fbias Sync
Speed Controller
Setpoint
Matching:
UM
The voltage matching function gives Regulator
the adjusting value to the internal
voltage regulator and the frequency
matching function send the analog T SM E
signal Fbias to the turbine regulator.
Monitoring and command generation:
The command to close the breaker
(CB) is released if all conditions are
fulfilled.
• After the power circuit breaker has been closed the Synchronize command must be
deactivated.
• The setpoint of the speed controller must have the nominal value of 50 resp. 60 Hz for the
synchronization.

Back-up channel system
Back-up channel
In case of a failure in channel 1,
UN 1000-15 / 1 UN 1000-15 / 2
the back-up channel 2 is
activated and the defective
channel switched off. Regulator Regulator
Change over to channel 1 can
be controlled by alarm signal or
with an external control signal. SM E
Alarm Standby
Activating the predefined digital inputs chooses operating modes. See section 5.2.
For further information how to design a redundant system please contact ABB.

2.4.2 Description of the parameters
System Data
- Nominal excitation current Ie Nominal [A]
- Measuring voltage three- or single- PT [Single_Phase] PTNET
UNET
phase [Three_Phase]
[Three_ph_gnd] f Nominal PTM
- Nominal voltage of the machine UM Nominal [kV] UM Primary UM Secondary Regulator
- Potent. transformer, primary voltage UM Primary [kV] IM2 Primary

- Potent. transformer, sec. voltage UM Secondary[V] IM2 Secondary
- Nominal machine current IM2 Nominal [A]
- Current transformer primary current IM2 Primary [A] IM2 Nominal
UM Nominal Ie Nominal
- Current transformer sec. current IM2 Secondary[A] Ie No Load
- No load excitation current Ie No Load [%] SM E
- Ceiling factor Kceil [V/V] Xq
- Machine reactance Xq [p.u.]
- Freq nominal f Nominal [Hz]
- Line voltage measurement (UNET) No scaling
IMPORTANT!
The line voltage measurement cannot be scaled.

If between PTM and PTNET a block transformer with any circuit configuration is
inserted,
the phase shift must be compensated.
FCB Control Field circuit breaker control
FCB Control is an option to control the field circuit breaker. The control is active, when the FCB
command signals are configured.
Excitation ON Input
1s
Close FCB Command Output
1s
Open FCB Command Output
FCB closed Status Input
PWM-Control
FCB closed Status FALSE Input

1s 1s
Alarm (MODBUS) Output

Field Flashing
Machine voltage
- Off Level Off Level [%] [%]

Signal field flashing
Field flashing off level

By setting Off level to 0% the field flashing is disabled
Soft start level
[s]
Excitation ON
Soft Start
Machine voltage
[%] UM Nominal
- Starting voltage Starting Level [%]
- Delay until ramp Hold Time [s]
- Ramp time Ramp Time [s]
Start level
[s]
A soft start is done only in the Auto mode
Hold time Ramp
Gen CB Closed Status = active

Trigger immediately the soft start
Limiters
V/Hz Limiter Machine voltage

- V/Hz knee point frequency fknee [Hz] [%]
- Slope Slope [%] 100
[Hz]
fknee
P [W] Active power

IeMinimum current limiter underexcited overexcited
- Minimum limit Minimum [%] Limiter-
characteristics GENERATOR
- Limiter active Active = True/False
Iemin Reactive power
Q- Q+ [var]
U M2
MOTOR
Xq

IeMaximum current limiter
Excitation current
- 1st limit Maximum [%] [%]
1st limit
- Hold time Maximum Hold Time [s]
2nd limit
nd
- 2 limit delay Delayed [%] Contin. current
- Hold time Delayed Hold Time [s]

[s]
Hold time Hold time
- Continuous current Continuous [%]
P [W] Active power

PQ Limiter
P=100%
underexcited overexcited
P=75%
The characteristic is determined by 5 points Generator
P=50%
- Q limit at P= 0% Minimum Q(P @ 0%) [%] P=25%

Reactive power
Q- Q+ [var]
- Q limit at P= 25% Minimum Q(P @ 25%) [%]
P=0%
P=25%

Motor
- Q limit at P= 100% Minimum Q(P @100%) [%]
- Voltage dependency active Volt.Dependency=True/False P=100%
UM Limiter (only in PF / Var mode)

- Limiting value of the minimum machine voltage Minimum [%]
- Limiting value of the maximum machine voltage Maximum [%]
- Limiter active Minimum Active = True/False
- Limiter active Maximum Active = True/False
IM Limiter
- Limiting value of the maximum machine current Maximum [%]
- Time Multiplier according to IEC 60255-3, Table 1, Time Multiplier K
Col. B, very inversed characteristic
- Limiter active Maximum Active = True/False

Boost-Output Machine voltage
Excitation ON
- Pick-up volt. to generate Threshold [%] Soft start
not active
boost command Excitation ON Voltage drop
100%
- Time boost output is Hold Time [s]
active
- Hysteresis for the reset Hysteresis [%] Hysteresis
of boost output Threshold
t
[s]
Hold time
Boost = 0 1 0
Voltage Relay= 1 0 1 0 1
Limiters Temperature Influence

IM Limiter Machine current IM
T1 at Max IM T1 [°] [%]
T2 at IM th2 T2 [°] Max IM P1
T3 at IM th3 T3 [°]
Im_th2 P2
T4 at IM = 0 A T4 [°]
Machine current level IM th2 [%] Im_th3 P3
Machine current level IM th3 [%] 25
P4 Cooling temp.
20 40 T1 T2 T3 T4 100 [°]
Excitation current Ie
Ie Limiter [%]
T1 at Max Continuous Ie T1 [°]
Max Continuous Ie P1
T2 at Ie th2 T2 [°]
T3 at Ie th3 T3 [°] Ie_th2 P2
T4 at Ie = 0 A T4 [°] Ie_th3 P3
Excitation current level Ie th2 [%] 25
Excitation current level Ie th3 [%] P4 Cooling temp.
20 40 T1 T2 T3 T4 100 [°]

Setpoint setting for the regulator
- Auto to voltage regulator
- PF, Var to power factor, reactive power regulator
- Manual, to manual regulator
- Open Loop to open loop regulation circuit
All setpoints have the following parameters

- Minimum
- Maximum
- Ramp Rate
Mode Preset value

Level of the setpoint if the digital input Excitation ON is not Manual 0%
active. Open Loop 0%
PF 1.0
Var 0%
Auto 100%
The limits and ramp rate can be set separately for each operating mode.
The setpoints of the non-active regulators follow the relevant operating point. For example, for
reactive power regulation (Var) the setpoint of the auto-regulator follows the current machine voltage.
Thus allows surge-free switching between operating modes if the new setpoint is within the setpoint
limit.
Particulars to the setpoint in Sync mode

- No Load: Regulator works in AUTO mode. Setpoint follows line voltage and the ramp rate
corresponds with the increase- resp. decrease command.
Voltage Droop Compensation Control (VDC)

- Primary Net ID Primary Net ID Machine voltage
- Secondary Net ID Secondary Net ID
- Ramp Time Ramp Up Time [s]
100
Ramp time to get machine voltage to 100% and Var

equal between machines after VDC is activated.
Reactive current
Var SPmax [%]

Var SPmin

Synchronization
- Minimum Slip Min Slip [Hz] (Delta U) UM -UNET [%]
- Maximum Slip Max Slip [Hz] 10.0
- Max. voltage difference MaxDeltaU [%] 5.0
Slip
Note: fM > fNET
[Hz]
Slip always negative -5.0
-10.0
-1.00 -0.40 0
Maximum Minimum
Angle = 10 -10
Delta Angle Max Delta Angle [deg] 20

0
-20
40 -20 -40
60 -60
80 -80
-Time between closing Tot CB Close Time [ms]

command and closed breaker
(see data sheet of the breaker)
- Correction factor voltage Voltage Offset [%]
- Correction factor of the Angle Offset [deg]
phase shift between UPWR and
UNET.
• Voltage matcher
The machine voltage is raised to the level of the line [%] Setpoint AUTO
voltage. 110 Maximum
UNET
Ramp Rate has to be adjusted in the menu Setpoint 103
Ramp = constant
AUTO
100
UM
98
90 Minimum
• Frequency matcher
Example: [Hz] Fbias
3
fNOM = 50 Hz (45 Hz < fNET 54 Hz, 50 Hz)
-0.8
(54 Hz < fNET < 66 Hz, 60 Hz) -3
fNET = 49 Hz
fM = 50 Hz
[Hz]
fSP = 50 Hz (Setpoint speed governor) fNOM
50
Slipmax = -0.4 Hz fSP + Fbias
fM 0.4
49.2
Slipmin = 0 Hz 49 fNET
Fbias = fNET -fNOM -(Slipmax-Slipmin)/2 = -0.8 Hz
fSP+Fbias= 49.2 Hz

Diode Monitoring
The aim of the Diode Monitoring is detecting the following failures:
- Break of a diode
- Short circuit of a diode
It is needed in brushless excitation systems and can only be done indirectly, because the diodes are
part of the rotor. See the principle circuit for the excitation is as follows:
Regulator
ie AC Exciter Synchronous Machine
Ie
- Nominal exciter frequency (Machine) f Exc Nominal [Hz]

- Exciter time constant Tconst Exc [s]
- Diode monitoring active Active = TRUE/FALSE
- Diode alarm level Alarm Level [%]
- Diode alarm delay Alarm Delay [s]
- Diode trip level Trip Level [%]
- Diode trip delay Trip Delay [s]
The device evaluates the alternating current induced in the field circuit of the exciter in the event of a
fault in the rotating rectifier.
The ALARM is triggered in the event of a broken branch in the rotating exciter.
The TRIP is triggered in the event of a branch short-circuit in the rotating exciter.

Power system stabilizer PSS
The PSS is used to improve the damping of possible oscillations in large transmission networks by
adding a signal to the voltage regulator of the existing excitation system.
It is also used to attenuate local rotor oscillation in synchronous generators through additional
influencing of the excitation. The main application is excitation systems in single or multi-machine
power plants.
Electromechanical oscillations may be classified in four main categories
• Local oscillations between a unit and the rest of the generating station and between the latter
and the rest of the power system. Their frequencies typically range from 0.8 to 2.0 Hz.
• Inter-plant oscillations between two electrically close generation plants. Frequencies may
vary from 1 to 2 Hz.
• Inter-area oscillations between two major groups of generation plants. Frequencies are in a
typical range of 0.2 to 0.8 Hz.
• Global oscillation characterized by a common in phase oscillation of all generators as found
on an isolated system. The frequency of such a global mode is typically under 0.2 Hz.
The IEEE Std. 421.5-1995 PSS 2A/2B type model functionally represents the PSS. This model is
showed in the following figure.
∆P RAMP-TRACKING LEAD-LAGS WITH OUTPUT

WASH-OUTS PSS-GAIN
INTEGRATOR FILTER ANTI WIND-UP LIMIT
PSS MAX
V1 s . TW1 s . TW2 + (1 + s ⋅ T8) N

+ 1+ s . T1 1+ s . T3 1+ s . T10 PSS
1+ s . TW1 1+ s . TW2
Σ (1 + s ⋅ T9) M
Σ KS1
1+ s . T2 1+ s . T4 1+ s . T11
(∆ω) _
+
PSS MIN
KS3
V2 s . TW3 s . TW4 KS2 +∆Pe'

1+ s . TW3 1+ s . TW4 1+ s . T7
(Pe)
The object of power system stabilizing (PSS) equipment is to increase the generator exciter‘s
contribution to improving the stability to the highest possible operating range of the generator.
The PSS derives additional signals from the generator internal frequency, which considerably
improves the stability of the power transmission.
• Dual input (frequency, electrical power).

The following figure shows an simplified diagram of the PSS and related functions.

Frequency
UM Calc
f

PSS
UM Power
IM2 Calc
Pe
Due to the PSS function implementation and structure of UNITROL 1000 AVR, there are some points
to be noticed when using this PSS. These are elements limiting the maximum performance of the
PSS:
• Brushless excitation system,

• Single phase machine current measurement (only) is available,
• Positive field voltage (only) can be supplied.
Parameters
The PSS function can be activated by PSS_SELECT parameter
The parameters will not be explained here. They can be calculated by ABB Switzerland. For further
information please see the Functional Description of UNITROL 1000, Power System Stabilizer,
3BHS213239 E01. See manufacturer’s details on page 2.

Regulator Tune
Auto [Voltage control] Gain
[p.u.]
- Proportional gain Proportional Gain Vp
- Derivative time constant Derivation Time Tb [s] 2 Vp
- Integral time constant Integration Time Ta [s] Vp
1/Ta 1/Tb 1257 ω [rad/s]
Machine voltage
nsati on
- Compensation or droop Droop Kq [%] [%]
Compe
Kq= 20% (max. compensation)
Kq= 0.00 (no effect)

Droop Kq= -20% (max. droop)
Reactive current
[%]
P [W] Active power

underexcited overexcited
PF or Var Control Var
and PQ Limiter PF Generator PF
Proportional Gain Vp
Derivation Time Tb [s]*) Reactive power
Integration Time Ta [s] Q- Q+ [var]
*) Only one parameter, see

voltage control Motor
Gain
Manual [p.u.]
Field current control and
Ie Limiter Vp
Proportional Gain Vp
Integration Time Ta [s]
1/Ta 1257 ω [rad/s]

Communication
- ID Definition ID unit number: AVR ID
- Port Configuration
- MODBUS For more information, refer to Modbus Manual
Write EEPROM
Saves the parameters in the device’s EEPROM
Electrically Erasable
Programmable Read Only Memory

3 INSTALLATION AND DISPOSAL
The unit should be unpacked with the usual degree of care, without the use of force and using
suitable tools.
The unit should be inspected visually to check for any damage caused during transport. Complaints
regarding defects resulting from inappropriate transport are to be addressed immediately to the
receiving station or the last carrier.
NOTICE!
The unit is visible damaged.
The safe operation is not possible.
The unit must not be installed and taken in operation
3.1 Mechanical installation O 7 mm 170 mm

UNITROLR 1000
The unit is fixed in place by means of four screws.

See dimensions diagram for fixing holes and spacing.
200 mm
Mounting instructions see page 9.
The unit should only be installed in indoor areas which are dry and dust-free
and which do not contain any gases, acid fumes or similar.
3.2 Earthing and wiring

The emission limits in accordance with standard EN 61000-6-4 will only be complied with if the
connections for the power electronics supply and the field output are made using shielded cables
earthed at each end. We also recommend that shielded cables be used for the analog and digital
connections.
The connection terminals are fitted on the front side of the unit, on three levels:
Cross sections: - Power electronics, terminal numbers 1 to 15: 0.2 to 4 mm2 (AWG 10 to 30)
- Electronic sections, terminal numbers 16 to 55: 0.2 to 2.5 mm2 (AWG 12 to 30)
The casing must be earthed at terminal 7 with 4 mm2. Additional earth terminals are provided for the
shielded cables. The earth connection should be kept as short as possible.
The tightening torque for all terminals is: 0.6 Nm (5 - 7 lbf. in.).
3.3 Disposal
Improper disposal of electrical devices can lead to environmental damage. It is
therefore important that qualified personnel carry out the disposal of electronic
equipment.
The metallic casing does not present any risk to the environment and can be recycled.
The printed circuit boards are simple to remove. The boards must be removed and
should be disposed by a licensed disposal company. Environmentally hazardous
elements such as capacitors must be separated from the boards.


4 OPERATION
4.1 Operation on the unit
4.1.1 Keypad
The keypad consists of four keys with the following functions:
Keys Commands
Select mode: Moves the cursor up or down
,
Horizontal arrow cursor marks the active line
Parameter setting: Increases or reduces value
OK Select mode: Selects sub-menu in the line marked with the cursor
On parameter level, the cursor disappears and the following text is
displayed:
OK to write value => Accept new value, not yet saved in EEPROM
ESC to cancel => Retain old value
Parameter setting: Accept new value
ESC Select mode: Back to next-higher menu
Parameter setting: Retain saved value
ESC+ Keys locked, panel light off
ESC+ Keys unlocked, panel illuminated
4.1.2 Display
After auxiliary voltage supply UAUX is applied the software revision

number of the unit (Cntrl) and the panel are shown on the display
for a few seconds. Then the start menu MAIN lights up.
All the sub-menus are called up from the “MAIN” start menu
The vertical arrow ( ! " # ) indicates whether other lines are available ! ∗∗∗
using the up ( $ ) or down ( % ) keys. →
The horizontal arrow cursor (→ →) marks the active line.
"MAIN" start menu

The title and three lines are displayed ! ∗∗∗ MAIN ∗∗∗
- Online measurement of machine and field values →Monitor
- Current operating mode, in this place only a information Mode = Auto
- Set ID number of the unit, in this place only a information Connected: 1
- Set parameters % key Setup
- Set regulator parameters % key Tune
- Set ID number % key Communication
- Save parameters in UNITROL 1000-15 % key Write EEPROM

4.1.3 Example of parameter setting
Example: Assigning Parallel wGrid to input DI6
Operating Key Resulting display
Display after auxiliary voltage is applied & ∗∗∗ MAIN ∗∗∗
→Monitor
Mode = Auto
Connected: 1
In the start menu, use %

setup
key to move down to
3x ▼ '∗∗∗
Mode
MAIN ∗∗∗
= Auto
Connected: 1
→Setup
Select sub-menu 1, setup, and use %

move down to digital I/Os
key to
OK, 7x ▼ '∗∗∗ SETUP
Setpoints
∗∗
Volt.Droop Comp.
→Digital I/Os
Select sub-menu 2, digital I/Os, and use %

to move down to I/Os
key
OK, 1x ▼ DIGITAL I/Os
Hysteresis
→I/Os
Din from Ain
OK, 5x ▼
Select sub-menu 3, digital I/Os, and use ' DIGITAL I/Os
% key to move down to DI6 DIO4
DI5
→DI6
Select sub-menu 4, DI6

OK ∗∗∗ DI6
→Din= None
∗∗∗
Polarity =Normal
Select parameter DI
Cursor disappears, text OK/ESC appears
OK ∗∗∗ DI6
Din= None
∗∗∗
- OK to write value
instead - ESC to cancel
Use $ key to select assignment

3x ▲ ∗∗∗ DI6 ∗∗∗
Din=Parallel wGrid
- OK to write value
- ESC to cancel
Press OK key to save

OK ∗∗∗ DI6 ∗∗∗
→Din=Parallel wGrid
Polarity =Normal
'
Press ESC key to return to start menu
4x ESC ∗∗∗
Mode
MAIN ∗∗∗
= Auto
Connected: 1
→Setup
• The above procedure only changes the parameters in the volatile memory. To make the
modification permanent, you have to save the entire parameter set:
• Save parameters: Start menu MAIN, Write EEPROM, OK, OK.

4.1.4 Menu structure of display
Start menu Sub-menu 1 Sub-menu 2 Sub-menu 3
∗∗∗ MAIN ∗∗∗

Monitor ∗∗∗ MONITOR ∗∗∗
Mode = Auto UM = kV
Connected: 1 UM rel = %
Setup IM2 = A
Tune IM2rel = %
Communication Q = kVar
Write EEPROM Q rel = %
P = kW
P rel = %
Ie = A
Ie rel = %
freq = Hz
MAIN ➠ ∗∗∗ SETUP ∗∗∗

System Data ∗ SYSTEM DATA ∗
Field Flashing UMNom = kV
Soft Start PT = PT:Three phase
Limiters UMPrim = kV Single phase
Synchronization UMSecond = V 3 phase gnd
Setpoints IM2Nom = A
Volt. Droop Comp. IM2Prim = A
Digital I/Os IM2Sec = A
Analog Inputs Ie Nom = A
Analog Outputs Ie NoLoad = %
Diode Monitoring Kceil = V/V
PSS f Nominal = Hz
Xq =
MAIN, SETUP ➠ ∗FIELD FLASHING

Off Level = %
MAIN, SETUP ➠ ∗∗SOFT START∗∗

Start Lvl = %
Hold Time = s
Ramp Time = s
MAIN, SETUP ➠ ∗∗∗ LIMITERS ∗∗∗

V/Hz Limiter ∗V/Hz LIMITER∗
IeMin Limiter fknee = Hz
IeMax Limiter Slope = %
PQ Limiter
UM Limiter
IM Limiter
Boost
Temp Influence

Sub-menu 2 Sub-menu 3
MAIN, SETUP, LIMITERS ➠ ∗ IeMin LIMITER ∗

Minimum = %
Active =
MAIN, SETUP, LIMITERS ➠ ∗ IeMax LIMITER ∗

Maximum = %
Hold Time = s
----------------------
Delayed = %
Hold Time = s
----------------------
Continuous = %
Active =
MAIN, SETUP, LIMITERS ➠ ∗∗ PQ LIMITER ∗∗

Q( 0%) = %
Q( 25%) = %
Q( 50%) = %
Q( 75%) = %
Q(100%) = %
Volt.Depend =
Active =
MAIN, SETUP, LIMITERS ➠ ∗∗ UM LIMITER ∗∗

Minimum = %
Maximum = %
MinActive =
MaxActive =
MAIN, SETUP, LIMITERS ➠ ∗∗ IM LIMITER ∗∗

Maximum = %
Time Mult =
Active =
MAIN, SETUP, LIMITERS ➠ ∗∗∗ BOOST ∗∗∗

Threshold = %
Hold Time = s
Hysteresis = %
MAIN, SETUP, LIMITERS ➠ ∗Temp Influence∗

IM Limiter Derating
Sub-menu 4
∗IM Limit Derating Ie Limiter Derating
T1 =
T2 =
IM th2 = %
T3 =
IM th3 = %
T4 =

Sub-menu 4
∗Ie Limit Derating
T1 =
T2 =
Ie th2 = %
T3 =
Ie th3 = %
T4 =
MAIN, SETUP ➠ SYNCHRONIZATION

Min Slip = Hz
Max Slip = Hz
Max dU = %
Max Angl = deg
TotCBCtime = ms
U Offset = %
Angle Off = deg
MAIN, SETUP ➠ ∗∗ SETPOINTS ∗∗

Auto ∗∗ AUTO
PF ∗∗ PF SP
Var ∗∗ Var SP
Manual ∗∗ MANUAL SP
Open Loop ∗ OPEN LOOP SP∗
Minimum = %
Maximum = %
Ramp Rate = %/s
MAIN, SETUP ➠ ∗∗∗ VDC ∗∗∗

Prim.NetID =
Sec.NetID =
Ramp Time = s
MAIN, SETUP ➠ ∗∗ DIGITAL I/Os∗∗

I/Os
Din from Ain

∗∗ DIGITAL I/Os∗∗
Sub-menu 4 DIO1
Direction: Input Din DIO2
∗∗∗ DIO1 DIO3
None, ∗∗∗ DIO2 DIO4
Excitation ON, ∗∗∗ DIO3 DI5
Gen CB cl. st., ∗∗∗ DIO4 ∗∗∗ DI6
Parallel wGrid, Direction = DI7
Increase, Din = DI8
Decrease, Dout =
Reset Setpoint, Polarity =
Remote SP Ena.,
PF Enable,
Var Enable,
Manual Enable, ∗∗∗ DI5
Open Loop Ena., ∗∗∗ DI6
Sync, ∗∗∗ DI7
VDC Enable, ∗∗∗ DI8 ∗∗∗
Secondary Net, Din =
Reset Alarm, Polarity =
Standby,
Fieldbus Block,
FCB Closed st.
Direction: Output Dout
None,
Boost, ∗∗ DIN from AIN ∗
Field Flashing, Sub-menu 4 DI9 from +AI
System OK, DI10 from –AI
Limit Active, ∗∗ DI09 DI11 from +AI
V/Hz Lim. Act., ∗∗ DI10 DI12 from –AI
SP Lim. Reach., ∗∗ DI11 DI13 from +AI
SP Min. Reach., ∗∗ DI12 DI14 from –AI
SP Max. Reach., ∗∗ DI13
Oper.Lim.Act., ∗∗ DI14 from –AI ∗
Min Ie Act., Din =
Max Ie Act., Polarity =
Min PQ Act.,
Min UM Act.,
Max UM Act.,
Voltage Relay,
Close CB Comd,
Sync Check,
SW Alarm,
Diode Alarm, Polarity: Normal,
Diode Trip, Inverted
SW or Di Trip,
Fieldbus Alarm,
FCB Close CMD,
FCB Open CMD

Ain: None,
Auto Remote SP,
PF Remote SP,
Var Remote SP,
Manual Rem SP,
OpenLoop R SP,
UM Aux,
Ie Ext [protected],
Cool Med Temp,
Reserved4,
Reserved5,
DI9(+)&10(-),
DI11(+)&12(-),
DI13(+)&14(-)
MAIN, SETUP ➠ ∗ANALOG INPUTS

AI1 ∗∗∗ AI1
AI2 ∗∗∗ AI2
AI3 ∗∗∗ AI3 ∗∗∗
UM Aux Ain =
Ie Ext [protected] Uin0% = V
Uin100% = V
MAIN, SETUP ANALOG INPUTS➠ ∗∗∗ UM AUX

∗∗∗ Ie Ext ∗∗∗
Minimum = A
Maximum = A
Aout: None,
Exc. Current,
PWM,
Fbias
MAIN, SETUP ANALOG OUTPUTS

AO1 ∗∗∗ AO1
AO2 ∗∗∗ AO2 ∗∗∗
Ie Range Aout =
Fbias Range Uout0% = V
Uout100% = V
MAIN, SETUP ➠ ANALOG ∗∗ Ie RANGE

OUTPUTS➠
∗ Fbias RANGE ∗
Fbias 0% = %
Fbias 100%= %

Sub-menu 1 Sub-menu 2 Sub-menu 3
MAIN, SETUP ➠ DIODE MONITORING

f Exc Nom = Hz
Tconst Exc= ms
Active =
Alarm Lvl = %
Alarm Dly = s
Trip Level = %
Trip Delay = s
MAIN, SETUP ➠ PSS

Active =FALSE
PSS Settings ∗ PSS SETTINGS∗
PSS Time Consts KS1 = pu
KS2 = pu
KS3 = pu
M =
N =
T7 = s
PSS max = %
PSS min = %
P min = %
MAIN, SETUP PSS➠ ∗PSS TIME CONSTS

TW 1 = s
TW 2 = s
TW 3 = s
TW 4 = s
T1 = s
T2 = s
T3 = s
T4 = s
T8 = s
T9 = s
T10 = s
T11 = s
MAIN ➠ ∗∗∗ TUNE ∗∗∗

Auto ∗∗∗ AUTO ∗∗∗
PF/Var/PQ Limiter Setpoint = %
Manual/Ie Limiter Vp =
Open Loop Ta = s
Tb = s
Kq = %
Step = %
Do Step

MAIN, TUNE ➠ PF/Var/PQ LIMITER

SP PF =
SP Var = %
Vp =
Ta = s
PF-Step =
Var-Step =
Do PF-Step
Do Var-Step
MAIN, TUNE ➠ MANUAL/Ie LIMITER

Setpoint = %
Vp =
Ta = s
Step = %
Do Step
MAIN, TUNE ➠ ∗∗ OPEN LOOP ∗∗

Setpoint = %
Step = %
Do Step =
MAIN ➠ ∗COMMUNICATION
AVR ID =
Modbus Setup MODBUS SETUP
Slave ID =
Active =
Bitrate =
Framing =
Protocol =
Answ Delay = ms
Keep Alive = s
KpAlive Act =
MAIN ➠ ∗∗∗ MAIN ∗∗∗

Write EEPROM
-OK to write value
-ESC to cancel
4.1.5 Fault message on the display

In certain circumstances it could appear the following fault messages on the display:
− XIRQ, SI or SYSTEM HALTED
The regulator continues to work faultless and has not to be taken out of service. But, no parameters
can be entered or changed.
The display is reseted when the unit is taken out of service and the auxiliary power is disconnected
for a short time.
A defective unit should be sent in for repair. See manufacturer’s details on page 2.

4.2 PC-Software
The delivered PC software is called CMT 1000 for UNITROL 1000-15.
System requirements: - at least Pentium II (200MHz) processor
- 256 MB RAM
- 4-speed CD-ROM drive
- Microsoft® Windows TM 95/98, NT, 2000, XP
Installing CMT 1000 4.x software

To install the CMT 1000 software please carry out the following steps:
• Place the CMT 1000 CD in your CD-ROM drive

• Open the Windows File Manager or Explorer
• Display the CD root directory
setup.exe
• Double-click Setup.exe from the directory CMT 1000 \ Installer
• Follow the instructions that appear on the screen. The Setup loads the
CMT 1000 program into your hard disk.
The application program is now installed.
To start the program: CMT 1000

• Open the user interface via Start button, Programs, UNITROL 1000-15 v4.3xx.exe
and Double-click the shortcut icon CMT 1000.
No communication between CMT 1000 and PC:

If CMT 1000 does not communicate with the PC, it has to be checked whether the interface COM x is
not adjusted or already occupied. See Port settings on page 65.
Port settings: Base I/O Port address: 3f8 (from windows control panel)
Interrupt Request Line (IRQ): 4
Distribution rights:
CMT 1000 was developed with the Lab VIEW software and is distributed free of license charges and
costs. The copyright to Lab VIEW is owned by the company National Instruments International
Distribution (NIID).
“Copyright © [02-03-20] National Instruments Corporation.“

4.2.1 Operation using the software
The window CMT 1000 is the graphic user
interface of the program. CMT 1000
File Monitor Setup Communication Tune Help
The other sub-menus are called up from
the menu bar: menu bar, start menu
OFF LINE
- File: Load/save parameters Connected to:

- Monitor: Online measuring ID-Number AVR1 EEPROM
- Setup: Set parameters
- Com.: Set ID number/ Port/ MODBUS
- Tune: Tune regulator
- Help: Software information
AB B CMT1000 for UNITROL 1000
Display on the unit:

After the connection cable has been connected, the unit display
reads REMOTE CONTROL. → REMOTE
CONTROL
To make the communication between CMT 1000 and the unit:

The cable connection should be attached only after switching on the power of UNITROL 1000-15.
It is possible to connect or disconnect the cable while the unit is in operation.
CMT 1000
k
clic
OFF LINE
• Click the button OFF LINE
ON LINE Button lights up green
Caution: This button is shaded, if Connected to: LED lights up green

CMT 1000 cannot communicate Reading Parameters from AVR AVR1 EEPROM
with the unit.
100.0% Ready
Cancel
Parameters Read OK
k
• Press the button „Continue“ to Clic
2nd
accept the reading of the Continue
parameters.
The button is now with ON LINE labelled and lights up green

The parameters have been loaded from the unit to CMT 1000 (EEPROM LED lights up green)

4.2.2 Example of parameter setting using CMT 1000
Example: Assigning Parallel with Grid Status to input DI6
Make ON-LINE connection to the unit
CMT 1000
Menu bar CMT 1000, start File Monitor Setup Communication Tune Help
menu
click System Data
- Select setup Soft Start
Field Flashing
Limiters
Setpoints
Voltage Droop Compensation
Digital I/Os
Analog Inputs
click Analog Outputs
Synchronization
- Select digital I/Os Diode Monitoring
PSS
+ Digital I/Os
Close
Direction Digital Input/Output Polarity
DIO1 In None Normal
DI5 None Normal
DI6 None Normal

k
ic
- Open input DI6 with % menu cl
None
Excitation ON
Gen CB Closed Status
Parallel with Grid Status
Increase
click Decrease
Reset Setpoint
- Select input Remote SP Enable
PF Enable
Var Enable
Manual Enable
Open Loop Enable
Synchronize
VDC Enable
Secondary Net
Reset Alarm
Standby
RC Fieldbus Block
FCB closed Status
DI6 Parallel with Grid Status Normal

Return to start menu
The above procedure only changes the parameters in the volatile memory.
To make the modification permanent, you have to save the entire parameter set.
Save parameters in ON LINE status:

- Unit: Menu bar CMT 1000 \ File \ Write Parameters to EEPROM
- Hard disk: Menu bar CMT 1000 \ File \ Save Parameter File

4.2.3 Menu structure of CMT 1000
CMT 1000
About CMT 1000… Software information
About CMT 1000
Control: Software revision unit CMT 1000

Panel: Software revision panel AB B for UNITROL 1000
Revision: 4.3xx
Revision: Software revision CMT 1000
Click window to continue Connected AVR

Software Revisions
Control:
Panel: Click window to continue

Open Parameter File *.ini (see the warning message below)
Save Parameter File saves the parameters to the PC hard disk
Write Parameters to EEPROM saves the parameters in the device’s EEPROM
Customer Setup user defined application, password detected

Close closes the application
[Open Parameter File] [Customer Setup] [Close]

Option for user defined See chapter 4.2.4, Save parameter
application file
User Password
Warning:
File does not contain Are you sure you want to close the Application?
SW version or incompatible Note: Parameters are not saved into EEPROM.
version found.
Cancel OK OK Cancel
Are you sure you want
to load parameter?
OK Cancel

Measurements Online measurement of the machine and field values
Oscilloscope Online measurement
PQ Diagram Online measurement
Sync Diagram Online measurement
Temp Influence ( IM Limiter
Ie Limiter
• Window measuring instruments

Monitor \ Measurements
Measurements
Close
- Network Voltage (UNet) [% and kV] Machine Voltage (UM)

- Machine Voltage (UM) [% and kV]
- Machine Real Power (P) [% and kW] 50 75 100
- Excitation Current (Ie) [A] 25 125
- Machine Current (IM2) [% and A] 0 150
- Machine Reactive Power (Q) [% and kVar]
- Network Frequency (fNet) [Hz]
- Machine Frequency (fM) [Hz]
- Power Factor (PF) -- 0.000 kV
0.0 %

• Oscilloscope
Monitor \ Oscilloscope
File Edit Start
Open Waveform Ctrl+O open the waveform (is saved as ASCII table, *.xls)
Recall Setup open settings of oscilloscope (*. cfg)
Save Waveform save measurements as ASCII table (*.xls)

Save Setup save oscilloscope settings (*. cfg)
Print Bitmap to File Ctrl+B save waveform in a BMP File
Close Ctrl+Q close application
File Edit Start

Cursors Ctrl+C show / hide cursors, Cursor appear on the left side of the screen
Sweep Buffer Ctrl+S Run through recording from Cursor A
File Edit Start

Start start the record (appears menu point Freeze Waveform)
Freeze Waveform stop the record (appears menu point Start)
File Edit Start Zoom

k
ic
Channel 1 cl Generator State
B
s A, UM Relative Mode
o r Combined Limit
rs 100.0 %/div
Cu -------------
0.0 % PWM
Ie Relative
Channel 2 UM Relative
f Machine IM2 Relative
f Machine
50.0 Hz/div P Relative
0.0 Hz Q Relative
cosphi
Channel 3 Iq Relative
Angle
Ie Relative
UNetRelative
50.0 %/div Slip
UM Step
0.0 %
PF Step
Var Step
Channel 4
Ie Step
PWM
100.0 %/div Gain
0.0 % Offset
Cursors A, B
A B
Channel 1 Channel 1
0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0 0.0 %
cl
ic
0.0 s
k
time / s
Channel 1
Buffer Length 50 s dt = 0.0 s Channel 2
1/dt = Inf Hz Channel 3
Channel 4
Abtastrate = 20 Abtastungen / Sekunde
Measurement: Define buffer length (max. length = 100 s)

Start, stop and save record
The assignment of the signal, gain, offset can be chosen afterwards.
A reduced buffer length improves considerably the performance of the PC.

• Window PQ Diagram
Monitor \ PQ Diagram (Power chart)
Close
125
100 Limiter characteristics
100 x
75
75 x
50 Operating points
50 x
25
25 x
0
0 x
-300 -275 -250 -225 -200 -175 -150 -125 -100 -75 -50 -25 0 25 50 75 100
75 75
The Limiter values can be moved by cursor
• Window Synchronization Diagram

Monitor \ Sync Diagram
Synchronoscope Differential voltage machine to network
UM - UNET [%]
Close command
Close
Angle Frequency/Voltage
10.0
0
20 -20 8.0
40 -20 -40
6.0
60 -60 4.0
Slip
2.0
80 -80 Synchronization x fM -fNET
0.0
100 -100 [Hz]
-2.0
120 -4.0
-120
-6.0
140 -140
-8.0
160 -160
180
-10.0
-0.8 -0.6 -0.4 -0.2 0.0 0.2 0.4
0.05 Hz

• IM or Ie Temperature Monitor
Monitor \ Temp Influence
IM Temperature Monitor Close
150
125
P1
100
P2
Current / [%] 75
P3
50
25
P4
0
0.0 0 2.0 10 4.0 20 6.0 30 8.0 4010.05012.06014.07016.08018.09020.0100
Cooling temperature / [%]
Ie Temperature Monitor Close
150
125
P1
100
P2
Current / [%]
75
P3
50
25
P4
0
0.0 0 2.0 10 4.0 20 6.0 30 8.0 4010.05012.06014.07016.08018.09020.0100
Cooling temperature / [%]
The Limiter values (Px) can be moved by cursor

Setting of the system and unit parameters
System Data System Data
Soft Start Soft Start
Field Flashing Field Flashing
Limiters ) Limiters
Setpoints ) Setpoints
Voltage Droop Compensation Voltage Droop Compensation Control
Digital I/Os Digital I/Os
Analog Inputs Analog Inputs
Analog Outputs Analog Outputs
Synchronization Synchronization
Diode Monitoring Diode Monitoring
PSS Power System Stabilizer
Limiters
V/Hz Limiter
Operational Limits PQ, Ie and UM limiter
Boost Line short circuit support
Temp Influence IM and Ie temp. monitor
Setpoints
Auto Min., max. and ramp
PF
Var
Manual
Open Loop

• Adjust System Data
Setup \ System Data
Close
Ie Nominal UM Nominal IM2 Nominal S Nominal

5.0 A 1.000 kV 500 A 0.87 MVA
Three Phase
Single Phase
Three ph gnd
Ie No Load Potential Transformer k Current Transformer
ic
30.0 % cl
PT Three Phase
Primary Secondary Primary Secondary Freq Nominal
Kceiling
1.000 kV : 110.0 V 500 A : 1.000 A 50.00 Hz
3.00 V/V
Xq
0.80 UM Nominal @ AVR IM2 Nominal @ AVR
110.0 V 1.000 A
• Configure Soft Start

Setup \ Soft Start
Close
110
Start Level 100
0.0 %
80
Hold Time 60
0.0 s
40
Ramp Time 20
10.0 s
0
0.0 0.0 2.02.0 4.04.0 6.06.08.08.010.0
10.0
12.0
12.0
14.0
14.0
16.0
16.0
18.0
18.0
20.0
20.0
• Adjust Field Flashing

Setup \ Field Flashing
Close
Field Flashing Off Level 0.0 %

• Adjust V/Hz Limiter
Setup \ Limiters \ V/Hz Limiter
Close
f knee 48.0 Hz
Slope 100.0 %/fknee
• Adjust Ie, UM, PQ and IM Limiter

Setup \ Limiters \ Operational Limits \ Limiter Setup
Ie Limiter Max Min
Close Close
Max Ie Max UM Max IM Max Ie Max UM Max IM

Min Ie Min UM Min Q Min Ie Min UM Min Q
Active Active
Max Ie = Min Q % for Min

160.0 Q s
10.0 Min Ie = 0.0Q %
Min
Max Delayed Ie = Min Q % for Min
120.0 Q s
60.0
Max Continous Ie = Min Q %
105.0
UM Limiter Max Min

Active Active
Max UM = Min Q %
110.0 Min UM = Min Q %
90.0
PQ Limiter IM Limiter
Close Close

Active Active
Voltage dependency
Max IM Min Q %
100.0
Min Q5 = Min Q %, when P = 100%
-20.0
Time Multiplier
-25.0 Min Q
1.00
K
-30.0
-35.0
-40.0

• Adjust Short Circuit Support
Setup \ Limiters \ Boost
Close
Threshold 40.0 %
Hold Time 3.0 s
Hysteresis 15.0 %
• Adjust Limiters Temperature Influence

Setup \ Limiters \ Temp Influence
Close
IM Limiter IM2 Nom 500.0 A Ie Limiter Ie Nom 5.0 A

Max
T1 50.0 ° Max IM 100.0 % T1 50.0 ° 105.0 %
Cont Ie
T2 60.0 ° IM th2 75.0 % T2 60.0 ° Ie th2 75.0 %
T3 70.0 ° IM th3 50.0 % T3 70.0 ° Ie th3 50.0 %
T4 80.0 ° 0.0 % T4 80.0 ° 0.0 %
IM and Ie can be changed only in “Operational Limits” on previous page.

• Adjust Setpoint Range
Setup \ Setpoints \ AUTO
Close
Minimum 90.0 %
Maximum 110.0 %
Ramp Rate 0.30 %/s
The setpoints PF, Var, Manual and Open loop are entered in identical input fields.
• Adjust Voltage Droop Compensation Control Range

Setup \ Voltage Droop Compensation
Close
Primary Net ID 1
Secondary Net ID 2
VDC Ramp Time 10.0 s

• Configure Digital I/O
Setup \ Digital I/Os
Close
Direction Digital Input/Output Polarity
DIO1 In None Normal

cl
cl
ic
ic
k
k
DIO2 In None
Out Normal
Inverted
DIO3 In None Normal
DIO4 In None Normal
DI5 None Normal
DI6 None Normal
DI7 None Normal
DI8 None Normal
DI9 from +AI None Normal
DI10 from -AI None Normal
k
ic
cl
Direction = In Direction = Out
None None
Excitation ON Boost
Gen CB Closed Status Field Flashing
Parallel with Grid Status System OK
Increase Limit Active
Decrease V/Hz Limit Active
Reset Setpoint SP Limit Reached
Remote SP Enable SP Minimum Reached
PF Enable SP Maximum Reached
Var Enable Operational Limit Active
Manual Enable Min Ie Active
Open Loop Enable Max Ie Active
Synchronize Min PQ Active
VDC Enable Min UM Active
Secondary Net Max UM Active
Reset Alarm Voltage Relay
Standby Close CB Command
RC Fieldbus Block Sync Check
FCB closed Status SW Alarm
Diode Alarm
Diode Trip
SW Alarm or Diode Trip
MODBUS Com Alarm
Close FCB Command
Open FCB Command

• Configure Analog Inputs
Setup \ Analog Inputs
Close
min max
UM Aux -10.0 % 10.0 %
Analog Input 0% 100%

AI1 None 0.0 V 10.0 V
AI2 None 0.0 V 10.0 V
AI3 None k 0.0 V 10.0 V

ic
cl
None
Auto Remote Setpoint
PF Remote Setpoint
Var Remote Setpoint
Manual Remote Setpoint
UM Aux
Reserved2
Cooling Media Temperature
Reserved4
Reserved5
Digital Input 9(+) & 10(-)
• Configure Analog Outputs

Setup \ Analog Outputs
Close
min max
Ie Range 0.0 % 300.0 %
PWM 0.0 % 100.0 %
Fbias Range -3.0 Hz 3.0 Hz
Analog Output
AO1 None 0.0 V 10.0 V
AO2 None 0.0 V 10.0 V

k
ic
None
cl
Excitation Current
PWM
Fbias

• Adjust Synchronization
Setup \ Synchronization
Close
Minimum Slip 0.00 Hz
Maximum Slip -0.40 Hz
Maximum Delta U 5.00 %
Maximum Delta Angle 10 deg
Total CB Closing Time 90 ms
Voltage Offset 0.0 %
Angle Offset 0.0 deg
• Adjust Diode Monitoring

Setup \ Diode Monitoring
Close
Active
Nominal Exciter Frequency 50 Hz
Exciter Time Constant 350 ms
Alarm Level 5.0 %
Alarm Delay 10.0 s
Trip Level 20.0 %
Trip Delay 0.3 s

• Adjust PSS
Setup \ PSS
Close
PSS_Select Activation Level

Active P min 5.0 %
Wash out time constants Gains
5.0 s PSS gain

TW1 5.0 s TW3 15.0 p.u.
factor KS1
Compensation factor for
TW2 5.0 s TW4 0.0 s 0.60 p.u.
power integration KS2
Signal matching
1.00 p.u.
factor KS3
Lead time constants Time constant Ramp tracking

of conditioning network for power integration filter time constants
T1 0.10 s
T7 5.00 s T8 0.00 s
T3 0.18 s
T9 0.10 s
T10 0.26 s
Lag time constants

of conditioning network
Ramp tracking
T2 0.02 s filter degrees Limits
M 5 PSS max 10.0 %

T4 0.02 s
N 1 PSS min -10.0 %
T11 0.02 s

ID Definition Set ID number
Port Configuration Set Port number
MODBUS Set MODBUS configuration
• Set ID Number Close

Communication \ ID Definition
ID 1
Required in VDC mode to be set unique
• Set Port Configuration

Communication \ Port Configuration ASRL1 (COM1-Communications Port)
ASRL1
none (COM1-Communications Port
ASRL2 (COM2-Communications Port
Push the button to select one of the ASRL10 (LTP1-Printer Port)
available COM-ports.
Cancel OK CMT 1000 must
be restarted
OK
• MODBUS RESERVED
RESERVED
Configuration RESERVED
115200
57600
38400
28800
19200
Close RESERVED
9600
4800
Slave ID Answer delay Bit rate 2400 Keep-alive time
247 10 ms 19200 b/s 0 sec
Protocol Character framing Keep-alive action

Active RTU Even none
RTU Even none
TCP Odd Set SW alarm
MODBUS register none Set fieldbus block
none Clear fieldbus request
Good messages
0 Address Data Integer
0 0 Bit
Hex
Bad messages
0
MODBUS register
Respond counter Address Code Data Integer

0 0 0 0 Bit
Hex

Setpoint Adjust
Auto Automatic voltage regulation
PF/Var/PQ Limiter PF, Var regulation and PQ Limiter
Manual/Ie Limiter Manual control and Ie Limiter
• Adjust Setpoint, Trigger Setpoint, Status Displays

Tune \ Setpoint Adjust
Close
Generator State Active Mode Limiter State Setpoint
A setpoint jump can
100.0 also be triggered in
Standby Ie High
this window.
95.0 105.0
Sync UM High
Grid
Manual
V/Hz
Sec. Net 90.0 110.0
Open Loop
IM High
Prim. Net DOWN UP Adjust setpoint
Pf
NoLoad 100.0 %
Var Ie Low
UM Step
VDC UM Low 0.0 % Set step height
AUTO Iq Low DOWN UP Trigger setpoint
jump
• Parameter Setting Range

Tune \ Auto
Close
Vp Ta
(Proportional Gain) (Integration Time)
100 10.00
75 125 - Tune \ PF/Var/PQ Limiter or
50 150 5.00 15.00 - Tune \ Manual/Ie Limiter
Close
25 175 Vp Ta
(Proportional Gain) (Integration Time)
0 200 0.01 20.00
100 10.00
20.0 4.00 s 75 125
50 150 5.00 15.00

Kq Tb
(Droop) (Derivation Time)
0 25 175
-5 5 2.00 3.00
0 200 0.01 20.00
-10 10 1.00 4.00 10.0 3.00 s
-15 15
-20 20 0.01 5.00
0.0 % 0.20 s

4.2.4 Save parameter file
PC UNITROL 1000-15
CMT 1000
RAM EEPROM
Parameters Parameters
Write Parameters
Harddisk Open Parameter File OFF LINE to EEPROM
Save Parameter File
ON LINE
EEPROM LED lights up, if data RAM = EEPROM (ON LINE)
• Status ON-LINE
After switching from OFF LINE to ON LINE, CMT 1000 reads the parameters from the device‘s
RAM. Now, all parameter changes carried out using CMT 1000 are written directly into the
device‘s RAM.
- Write Parameters to EEPROM: The parameters in the RAM are stored in the device.
- Save Parameter File: The parameters are saved onto the hard disk as an INI file.
- Open Parameter File: The INI file is loaded into CMT 1000 and the RAM is
overwritten again.
When opening a parameter file from disk, the old parameter file is immediately overwritten in the
RAM!
• Status OFF-LINE
Any parameter changes carried out in CMT 1000 are not transferred into the device.
- Write Parameters to EEPROM: No effect, since there is no communication between CMT
1000 and the device.
- Save Parameter File: The parameters are saved onto the hard disk as an INI file.
- Open Parameter File: The INI file is only loaded into CMT 1000.
If you now switch to ON-LINE, CMT 1000 reads the old data from the RAM again!

4.2.5 Evaluation of the waveform
The curves for the current and stored data can be viewed using the oscilloscope, PQ diagram and
the instruments. (Monitor toolbar)
Close
Measurements
Close
125 Voltage [UM]

Machine
100 Limiter characteristics
100
50 75
x
100
25 125 75
75 x
0 150
50 PQ Limiter is active
50 x
25
25 1.067 [kV] x
0
106.7 [%]
0 x
Zoom -300 -275 -250 -225 -200 -175 -150 -125 -100 -75 -50 -25 0 25 50 75 100
File Edit Start
Freeze Waveform
Channel 1
UM Relative
1 100.0 %/div
0.0 %
Channel 2
1 Iq Relative
100.0 %/div
2 2
0.0 Hz
B Channel 3
4 Combined Limit
1.0 /div
0.0
Channel 4
A 3 3 Gen. State
2.0 /div
4
0.0
Cursors A, B
A B
Channel 3 Channel 3
0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0 0 3
20.0 s 30.0 s
time / s Sweep Buffer
Buffer Length 50.0 s dt = 10.0 s
1/dt = 0.010Hz
• Status OFF LINE

File \ Open Waveform: Open stored waveform file.
Edit \ Cursors: Assign channel with buttons A and B, use left mouse button to drag
cursor A to the desired point on the signal curve. The measured values
can be measured on the oscilloscope, instruments or PQ diagram.
Edit \ Sweep Buffer: The curves are run through from cursor point A using the scanning bar.
• Status ON LINE
Start: The recording of the waveform is started.
Freeze Waveform: The recording is stopped.
File \ Save Waveform: Save waveform.
File \ Save Setup: Save oscilloscope settings.
− The window in “Tune“ can also be opened to set the regulators.

− The setpoint step is simulated in “Tune Setpoint Adjust“.
− The buffer length can be adjusted from 1 s, 2 s, 5 s, 20 s, 50 s to 100 s.
− The time scale can be adjusted in the bar above the waveform (Zoom).

Monitor \ oscilloscope, status display
There are 3 quasi analog signals which can be used to represent status changes on the oscilloscope.
Decoding of the signals Generator State, Mode and Combined Limit.
signal value state

Generator State Generator State: 0 = Idle (NoLoad)
Mode 1= Change NoLoad -> Primary Net
Combined Limit
------------- 2= Primary Net
PWM 3= Change Primary Net <-> Secondary Net
Ie Relatve 4= Secondary Net
UM Relative 5= Change Secondary Net -> NoLoad
IM2 Relative 6= Primary Net or Secondary Net -> Grid ON
f Machine
P Relative
7= Grid ON
Q Relative 8= Grid ON -> Primary Net or Secondary Net
cosphi
Iq Relative Mode: 0= Auto
Angle 1= Var
UNetRelative 2= PF
Slip 3= Manual
UM Step
PF Step
4= Open Loop
Var Step 5= VDC
Ie Step 6= Sync
7= Standby
Combined Limit: 0= None
1= Min Ie Active
2= Min UM Active
3= Min PQ Active
4= Max Ie Active
5= Max UM Active
+8 = V/Hz Limit Active*)
+16 = SP Minimum Reached
+32 = SP Maximum Reached
+64 = Diode Alarm
+128 = Diode Trip
+256 = Max IM active
Excitation ON active Combined Limit = See signal value

Excitation ON not active Combined Limit = -1.0
*) Each time a limiter is tripped, the V/Hz-Limiter, outside of the Setpoint Range and or the Diode
Monitoring can also occur and be displayed in the status signal of the limiters. All other collective
signals only allow one display.

Summary of the limiter status:
Combined Limit
Max UM Active + V/Hz 13.0
Max Ie Active + V/Hz 12.0
Min PQ Active + V/Hz 11.0
Min UM Active + V/Hz 10.0
Min Ie Active + V/Hz 9.0
V/Hz Limit Active 8.0
+8
Max UM Active 5.0

Max Ie Active 4.0
Min PQ Active 3.0 +8
Min UM Active 2.0
Min Ie Active 1.0 s
None

4.2.6 Error message
• Error message during the reading of the parameters
The following message appears if the connection is interrupted during the reading of the parameters.
Error 0 occurred at Time Out.
Possible reasons:
This error code is not listed in the internal database, or

you have wired a number that is not an error code (such
+ PCTools as a DAQ task ID) to the error code input.
Reading Parameters from AVR
100.0% Ready
OK
Cancel
ON LINE
− Acknowledge by clicking on the Continue button.

− Check connection between PC and device and click OFF LINE button again.
• Error message at assigning of the digital input with the signal Synchronize, Diode Monitoring
respectively PSS.
The Error message appears, when the relevant unit does

not include the option Synchronization, Diode Monitoring
respectively PSS. Synchronization is not possible with this unit
OK
Diode Monitoring is not possible with this unit
OK
PSS activiation not possible
OK
You can ask for information directly from the manufacturer, in case the option “Synchronization“,
“Diode Monitoring” respectively “PSS” is required to this unit.
See manufacturer’s details on page 2


5 COMMISSIONING
5.1 Safety regulations
WARNING!
! UNITROL 1000-15 units operate with dangerous voltages of up to

250 VAC.
Manipulation of live parts can lead to death or injury to the persons

involved or damage to the surroundings.
Possible risks are largely excluded if the unit is handled properly in

accordance with these instructions.
WARNING!
! The secondary voltage of the excitation transformer and the voltage of

the excitation field are fed into the excitation cabinet.
These components present a great danger of electric shocks.
The control elements and the PC interface on the front plate of the
UNITROL 1000-15 unit are to be touched and/or attached only under
large caution.
After the unit has been switched off, it must be ensured by measurement that no measuring voltages
or control voltages >50 V are present at the terminals. At an interrupted field circuit the input
capacitor is slowly discharged through internal circuits.
In order to prevent unintentional closing of open voltage circuits by third parties, the circuits in
question should be identified at the point of interruption (e.g. by means of a warning sign).
Before switching on, check whether the connection terminals are wired up according to the plant
schematic.

5.2 Setting aids
At the first commissioning all parameters have to be controlled.
For this see description of the parameters in section 2.4.2 and settings recorded in section 7.3.
Overview of parameter blocks

• Setup: - System Data
- Soft Start
- Field Flashing
- Limiters
- Setpoints
- Voltage Droop Compensation Control
- Digital I/Os
- Analog I/Os
- Synchronization
- Diode Monitoring
- Power system stabilizer (PSS)
• Tune: Controller
• Communication: ID unit number/ Port/ MODBUS.
Setting aids
• Setup \ System Data, Ceiling Factor Kceil
The following section describes how to determine the Ceiling Factor in two different ways.
We recommend the measuring method.
Measuring method
Ue max 100 U PWR

K ceil = =
Ueo PWMnoload
UM Nominal
Uemax: maximum output voltage
Ueo: output voltage at nominal Regulator
voltage of the machine
(machine in no-load operation) U emax
PWM no load: Regulator output at no load SM E U eo
(PWM)
Definition: The ceiling factor Kceil determines the relationship between the maximum output
voltage of the regulator and the exciter voltage, which is required for no-load excitation
and is thus a measure for the possible overexcitation of the machine.
Example: Regulator output signal (PWM) at no load shows 20% at nominal voltage
100
K ceil = =5
20

Calculating method
Power electronics supply: three- phase: Uemax = 1.40 * UPWR – 8 V
single-phase: Uemax = 1.25 * UPWR – 8 V
DC: Uemax = 0.98 * UPWR – 8 V
Example:
Specifications: Power electronics supply UPWR = 240 V, single-phase
No-load exciter voltage Ueo = 50 V
Calculation: Uemax = 1.25 * 240 V – 8 V = 292 V

Kceil = 292 V/50 V = 5.8 p.u.
• Setup \ System Data, Machine Reactance Xq (non-saturated)

- Salient pole machine: Xq * 0.7 to 0.5 Xd
- Cylindrical-rotor machine (Turbo): Xq * Xd
• Setup \ Limiter, Manual and Open Loop

There are no limiters active in the mode Manual and Open loop.
• Setup \ Limiter, UM Limiter

The limiting values of the UM limiter are, as a rule, set equally, like the setpoint range of the
voltage regulator (Auto mode).
Setpoint Auto UM Limiter Example

Minimum = Minimum 90%
Maximum = Maximum 110%
• Setup \ Digital I/Os, configuration

Software configuration of the digital I/Os:
− Check switching threshold of the inputs. Default values apply to internal 24 V supply.
− Define terminal as input or output
− Assign terminal to desired signal
− Select polarity
• Setup \ Analog inputs / outputs, configuration

Software configuration of the analog inputs:
− Define signal level of the input signal [Uin 0% to Uin 100%]
− If the input is used as a digital input, the desired signal name is to be assigned in the menu
Digital I/Os.
Software configuration of the analog outputs:

− Define signal level of the output signal [Uout 0% to Uout 100%]
− Define signal level of the field current [Ie 0% to Ie 100%]

• Setup \ Digital I/Os, selection of operating mode
The operating mode is selected via the digital inputs. For this purpose, a maximum of 10 inputs
have to be occupied by the following signals:
Mode Digital inputs which are to be assigned

Stand SYN Gen CB Parallel Manual Open VDC PF Var
by Closed with Enable Loop Enable Enable Enable
Status Grid Enable
Status
Standby 1 X X X X X X X X
Sync 0 1 X X X X X X X
Manual 0 0 X X 1 X X X X
Open Loop 0 0 X X 0 1 X X X
VDC 0 0 1 0 0 0 1 X X
PF 0 0 1 1 0 0 0 1 X
Var 0 0 1 1 0 0 0 0 1
Auto 0 0 0 X 0 0 X X X
with *) 0 0 1 X 0 0 0 0 0
*) with droop or compensation
0 = logical 0 or open 1 = logical 1, X = not relevant
Note: If an input is to be continuously logical 1, then it can also be inverted by software means.
The input then naturally counts as being occupied.
The inputs DI9 to DI14 can be used as virtual digital inputs even if they are not defined in
Analog Inputs as Digital Inputs.
• Setup \ Synchronization
The machine frequency has to be always greater than network frequency.
It cannot be synchronized by a positive slip.
• Setup \ Diode Monitoring

The Nominal and the Nominal Exciter Frequency have to be adjusted, for the other keep the
default value.
Nominal Exciter Frequency = p x n/60 p = Number of poles pairs [.]
n = Revolutions per minute [U/min]
• Setup \ PSS
The parameters can be calculated by ABB Switzerland. For further information please see the
Functional Description of UNITROL 1000, Power System Stabilizer, 3BHS213239 E01.
See manufacturer’s details on page 2.

• Tune \ Setpoint Adjust, Step
Mode Maximum adjustable setpoint jump during 10 s

Manual ±50%
Open Loop ±20%
PF ±0.2
Var ±50%
Auto ±20%
• Tune, Order of priorities

If several operating modes are selected simultaneously by the digital inputs, then the following
order of priority applies. This is also shown in the tables Selection of operating mode on the
preceding page.
Priority Mode Remark
1. resp. top Standby
2. Sync
3. Manual
4. Open Loop
5. VDC Only active, if Gen CB Closed status is active and Parallel
with Grid status is not active
6. PF Only active, if Parallel with Grid status is active
7. Var Only active, if Parallel with Grid status is active
8. resp. lowest Auto Active, if no other operation mode is active
• Tune, Auto
The following settings can be pre-set on the basis of the machine data.
Integral time constant Ta

This lies within the range of Td‘ of the main machine.
Setting: Ta = Td‘ (Typically value 2 to 5 s)
Derivative time constant Tb

This approximately compensates the load time constant TE of the exciter machine.
Setting: Tb = 0.7 to 1.0 * TE (Typically value 0.1 to 0.3 s)
Proportional gain Vp
This most important setting value depends primarily on the controlled system.
If the ceiling factor Kceil has been set correctly, values between 10 and 40 should result in stable
regulation of the machine.
A default value of 20 is set for the first excitation.
Reactive power influence Kq

In the case of machines which, without step-up transformers, are connected with the fixed grid or,
via a busbar, with other synchronous machines, it is essential that the droop Kq is set to a
negative value of -5 to -20%. A higher negative value makes the machine more independent of

voltage fluctuations in the grid; the reactive power output or consumption stabilises. At low
negative values, the machine will support the grid or busbar voltage.
In the case of machines with step-up transformers, the voltage drop of the transformer can be
partly compensated with positive values of Kq.
Example: Step-up transformer Reactance = 12%

Compensation Kq = +6%
• Communication \ MODBUS
The RS485 port is shared between VDC mode and MODBUS. With factory settings, MODBUS is
disabled.
To use MODBUS, the parameter MB_Enable must be set true, then the parameters have to be
written to the EEPROM. Afterwards, the UNITROL 1000 must restart by power cycling. This
procedure has to be followed for any change to MODBUS related parameters to take effect. It
serves as a protection against inadvertently overwriting the setup through MODBUS itself and
therefore loosing connection to the UNITROL 1000.
- Standard configuration for: - Answer Delay: 10 ms

- Bit rate = 19200
- Character Framing = even
- RTU: protocol of the RS485
- Slave ID:
Zero and values greater 247 are reserved, so the valid range for the slave ID is 1 t0 247, with 247
as default.
- Keep-alive time:
The parameter “MB_KeepAliveTime” defines, in which period of time the “Keep Alive Bit” in
control word 1 must be changed. Valid settings are 1 to 120 seconds and 0 to disable the
connection monitoring.
- Keep-alive action:
If the timer reaches the supervision time a “Modbus Communication Alarm” will appear and one
of the following event can be selected with the “MB_KeepAliveAction”.
For more information, refer to Modbus Manual

5.3 Work carried out while machine is at a standstill
Preliminary checks:
• Wiring check, compare connections with schematic
CAUTION!
Check of the insulation strength of the plant with the insulation tester
During the test the equipment could damage by the testing voltage.
Disconnect cables to the UNITROL 1000-15.
• Switch on auxiliary voltage UAUX

• Adjust parameters
• Check measuring voltage and current transformer circuits
• Measure field resistance
• Low-load test: External power electronics supply (3x <250 V AC)
- Open loop mode
- Optimise regulator Ie
• Adjust limiter settings on the basis of customer’s power chart
5.4 Work carried out while machine is running

No-load tests: (nominal speed, not synchronized)
• Field flashing and discharge in Auto and Manual mode

• Soft start in Auto mode
• Adapt setpoint range, optimise voltage regulator
• V/Hz limiter: The actuation point fknee is set to 48 Hz by default
For 60 Hz machines this value must be set to approximately 58 Hz.

Tests under load:
• Stator current measurement, internal P- and Q-measurement, droop/compensation

The droop/compensation is set to 0% by default. If the machine is paralleled directly with the rigid
grid or, via a busbar, with other synchronous machines, it is essential that the droop Kq is set to a
value of approx. –10% before the first synchronization. The reactive current must be monitored
carefully during the first paralleling. If it increases uncontrollably following the first synchronization,
then the current polarity of the IM2 measurement is incorrect or the CT phase position is wrong.
• Load rejection overexcited and underexcited

• Optimise Iemin / Iemax Limiter
• Optimise PQ Limiter
The setting of the PQ limiter must be co-ordinated with the settings of the generator protection. As a
rule, the limiter should be set at least 5% lower.
• PF and Var regulator, stability, setpoint range.

To enable correct operation of PQ Limiter, the PF / Var regulator must be tuned, even if these modes
are not used.

Synchronization:
It is a prerequisite for the correct functioning of the synchronization

that there is no error in phase or magnitude between UNET and UM, UN 1000-15
caused by wrong connection or ratio of PT’s on the grid side and UNET
generator side. CB AVR
UM
• Measurement of the phase angle of the voltages UNET and UM:
Open the isolator, close the circuit breaker (CB) Isolator
For reasons of safety has to be measured not only in the menu
Monitor\Oscilloscope or Monitor\Sync Diagram but also with an SM
oscilloscope.
• „Blind“ synchronization:
Watch the event with synchronoscope (Monitor\Sync Diagram)
by disconnected trigger of the circuit breaker.
• „Live“ synchronization:
Record the event with synchronoscope
• About the measurement:
CAUTION!
In this status, the phase-angle difference must be 0 deg. Otherwise the

measuring cable are incorrectly connected. Incorrect polarity cannot be
detected by the UNITROL 1000-15.
Paralleling with incorrect polarity can lead to serious damage.
There must not occur a phase shift caused by one of the both measuring
transformer or by the connection group of a step-up transformer.
The synchronoscope must stand at „twelve o’clock “. If the synchronoscope stands at „six o’clock“,
one voltage is incorrectly connected. In other positions, either measuring is being carried out on
incorrect phases or a phase shift caused by the connection group of a step-up transformer has not
been compensated.
Concluding work:
• Saving the parameter and write the parameter settings section 7.3 or printing out the INI file.
The INI file can be opened using an editor (Word, Note- or WordPad) and printed out.


6 MAINTENANCE AND FAULTS
6.1 Safety regulations
WARNING!
! The secondary voltage of the excitation transformer and the voltage of

the excitation field are fed into the excitation cabinet.
These components present a great danger of electric shocks.
The control elements and the PC interface on the front plate of the
UNITROL 1000-15 unit are to be touched and/or attached only under
large caution.
6.2 Maintenance
When the system is at a standstill, the screwed terminals, which can loosen due to vibrations should
be checked for tightness. Dusty cooling flanges should also be cleaned.
6.3 Trouble shooting

The following instructions are intended to assist in localising a fault within the excitation system as a
whole. However, it is not possible to deal with all eventualities in full.

List of possible faults
Possible causes Checks, action

Machine is not excited
• Field circuit interrupted − Check wiring for break

• Field circuit-breaker doesn’t close − Check field circuit-breaker
Shunt supply:
• Field flashing does not work − Check field flashing circuit
• No electronic supply UAUX − Measure auxiliary supply UAUX

− Check for tripped protective circuit-breaker
• No control element supply UPWR − Measure power electronics supply UPWR

Shunt supply:
• Machine is only excited to the value supplied − Measure auxiliary supply UAUX,
by the field flashing Measure power electronics supply UPWR
− Check field flashing Off level
• Machine is first excited then discharges − Check operating mode. For field flashing
again normally Auto is used
− Check field flashing Off level
− Check setpoint
− Measure power electronics supply UPWR
− If all supplies and setpoints are correct
change unit
• Setpoint error − Check operating mode. For field flashing
normally Auto is used
− Check setpoint
• Regulator error − Measure output voltage at terminals 8, 9

(Osc.) -> positive
− Measure voltage UPWM (CMT 1000, Monitor)
-> positive rising

Overvoltage during build-up
• Overvoltage caused by voltage regulator − Machine voltage UM present

− Check system data
− Check operating mode. For field flashing
− Check setpoint
− Check thresholds of UM Limiter
− Check regulator settings
• Field flashing current too high − Check design of the field flashing circuit.
Field flashing should deliver 10 to 15% of
the no load excitation current
Machine voltage not stable in no-load

operation
• Regulator error − Check operating mode. For field flashing

− Check setpoints
− Check parameters of Auto regulator
• Setpoint error − Higher, lower inputs unstable

− Externally input setpoint unstable
• Control element fault − Check wiring, loose contact UM, Ie
Parallel operation with grid unstable.

Periodic oscillation of reactive and possibly active power
• Regulator settings incorrect Were changes made to the grid configuration?

Additional outputs, loads etc. installed?
− Yes: re-set regulator

− No: check parameters of Auto and PF, Var
regulator

Irregular instability, i.e. sporadic over- or underexcitation which is not caused by grid
• Droop influence of the voltage regulator − Check droop/compensation setting

ineffective or IM2 measurement defective − Check external current transformer circuit
− Gen CB Closed Status not active
• Machine within inadmissible operating range − Bring machine into normal operating range
(normally protected by limiters) by adjusting the setpoint.
− Check setting of limiters
• Regulator fault Measure output voltage at terminals 8, 9

(oscilloscope)
Measure voltage UPWM (CMT 1000, Monitor)
− Signals in phase opposition: unit defective

− Signals in phase: disturbance possibly
caused by the driving side of the machine or
by disturbances from the grid
Operating point cannot be adjusted
• Setpoint error − Check operating mode. For field flashing

− Check setpoint
• Limiter active − Bring machine into normal operating range

by adjusting the setpoint.
− Check setting of limiters
Excitation with compounding and boost circuit:

Excitation is only supplied by the series
compounding
• No control element voltage − Measure power electronics supply UPWR

• Regulator fault − Check operating mode. For field flashing

− Check setpoint
− Check parameters of Auto regulator

External controls faulty
• No external control voltage − Measure control voltage

− Check wiring
• No internal control voltages Vdig, Vref − Measure internal control voltages
• Configuration of the digital or analog inputs or − Check configuration

outputs is not correct
6.4 Repair
The unit may not be opened. A defective unit should be sent in for repair with failure description and
if possible, trending of failure. See manufacturer’s details on page 2.


7 APPENDIX
7.1 General Data

Ordering information
Device designation UNITROL 1000-15, V4
Order number Basic equipment 3BHE014557 R00x3
with Synchronization 3BHE014557 R00x4
with RDM 3BHE014557 R00x5
with Synchronization and RDM 3BHE014557 R00x6
without PSS 3BHE014557 R000x
with PSS 3BHE014557 R001x
with MODBUS 3BHE014557 R002x
Mechanical data
Weight 5 kg
Protection class IP20
Dimensions (HxWxD) 245x190x142 mm
Climatic stability
Temperature range for operation 0 to 60 °C
Temperature range for storage -20 to +75 °C
Vibration 2 mm f<15 Hz, 0.7 g f>15 Hz
Shock 5 g, 11 ms pulse
Electrical data
Auxiliary supply UAUX: Maximum power consumption 25 W
Power electronics supply UPWR: Frequency DC, 40 to 600 Hz
Excitation output IM2: - Maximum continuous current 15 A
- Current reduction for ambient temperatures >50 °C 1 A /degree
- Overload (maximum 10 s) 30 A DC
- Overload (maximum 4 min) 20 A DC
Frequency range of measuring values UM and IM2 10 to 100 Hz
Accuracy: Voltage regulation <0.1%
Test voltage:
Power electronics supply UPWR against case and auxiliary supply UAUX 2830 V DC, 2 s
Auxiliary supply UAUX against case and power electronics supply UPWR 2830 V DC, 2 s
Voltage measurement inputs UM, UNET: High impedance voltage input without galvanic separation
According to (USA, Canada) UL specification:

The screw-type terminals for inputs and outputs are approved for maximum voltage 150 V
Relevant standards, CE conformity

EMC directive: 89/336/EEC
Generic emission standard IEC/EN 61000-6-4
Generic immunity standard IEC/EN 61000-6-2
Ordering information connection cable PC to UNITROL 1000-15

Series standard cable (terminals 2 and 3 crossed) DB9 f/f/ 3 m

7.2 Settings record for UNITROL 1000-15
Name and address of customer: __________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
Plant: __________________________________________________
Order no.: __________________________________________________
Plant schematic no.: __________________________________________________
Device identification:
Type plate: __________________________________________________
Delivery date: __________________________________________________
Software revision: - Control: __________________________________________________

- Panel: __________________________________________________
- CMT 1000: __________________________________________________
Remarks:
Place and date of commissioning:
Name: Company:

7.3 Parameter settings, default values
Parameter Parameter Standard Setting range Set Unit
INI-File value
System Data [SYSTEM DATA]
- Nominal excitation current Ie Nominal 5.0 0.1 to 1000.0 A
- Measuring volt., three- or single-phase Potential Transformer Three_ Three_Phase /
Phase Single_Phase /
Three_ph_gnd
- Nominal voltage of the machine UM Nominal 1.000 0.010 to 32.000 kV
- Potential transformer, primary voltage UM Primary 1.000 0.010 to 32.000 kV
- Pot. transformer, secondary volt. 3-Ph UM Secondary 110.0 60.0 to 250.0 V
1-Ph 60.0 to 150.0 V
3-Ph gnd 60.0 to 150.0 V
- Nominal machine current IM2 Nominal 500 1 to 32000 A
- Current transformer primary current IM2 Primary 500 1 to 32000 A
- Current transformer secondary current IM2 Secondary 1.000 0.500 to 1.500 A
- No-load current Ie No Load 30.0 0.1 to 100.0 %
- Ceiling factor Kceiling 3.00 1.00 to 100.00 V/V
- Machine reactance Xq 0.80 0.20 to 4.00
- Frequency nominal f Nominal 50.00 10.00 to 200.00 Hz
Field Flashing [FIELD FLASHING]
- Reached voltage off level Off Level 0.0 0 to 95.5 %
Soft Start [SOFT START]
- Starting voltage Starting Level 0.0 0 to 100.0 %
- Delay until ramp Hold Time 0.0 0 to 327.0 s
- Ramp time Ramp Time 10.0 0 to 327.0 s
Limiter
V/Hz Limiter: [V/Hz LIMITER]
- Cut-off frequency fKnee 48.0 10.0 to 200.0 Hz
- Slope Slope 100.0 0 to 327.0 %
IeMin Limiter: [IeMin LIMITER]
- Minimum limit Minimum 0.0 0 to 150.0 %
- Limiter active Active FALSE TRUE / FALSE
IeMax Limiter: [IeMax LIMITER]
st
- 1 limit Maximum 160.0 0 to 400.0 %
- Delay time Maximum Hold Time 10.0 0 to 327.0 s
nd
- 2 limit Delayed 120.0 0 to 300.0 %
- Delay time Delayed Hold Time 60.0 0 to 327.0 s
- Continuous current Continuous 105.0 0 to 150.0 %
- Limiter active Active TRUE TRUE / FALSE
PQ Limiter: [PQ LIMITER]
- Q Limiter at P = 0% Minimum Q (P @ 0%) -40.0 -400.0 to -0.5 %
- Q Limiter at P = 25% Minimum Q (P @ 25%) -35.0 -400.0 to 0 %
- Q Limiter at P = 100% Minimum Q (P @100%) -20.0 -400.0 to 0 %
- Voltage dependency active Voltage Dependency TRUE TRUE / FALSE
- Limiter active Active TRUE TRUE / FALSE

INI-File value
UM Limiter: [UM LIMITER]
- Limiting value mini. machine voltage Minimum 90.0 0 to 150.0 %
- Limiting value maxi. machine voltage Maximum 110.0 0 to 150.0 %
- Limiter low level Minimum Active TRUE TRUE / FALSE
- Limiter high level Maximum Active TRUE TRUE / FALSE
Boost: [BOOST]
- Minimum machine voltage Threshold 40.0 0 to 100.0 %
- Time boost output is active Hold Time 3.0 0 to 32.0 s
- Hysteresis Hysteresis 15.0 0 to 100.0 %
Range of Setpoints
Auto: [AUTO SETPOINT]
- Minimum value Minimum 90.0 0 to 150.0 %
- Maximum value Maximum 110.0 0 to 150.0 %
- Ramp rate Ramp Rate 0.30 0.01 to 100.00 %/s
PF: [PF SETPOINT]
- Minimum value Minimum -0.8500 -0.2500 to +0.2500
- Maximum value Maximum 0.8500 -0.2500 to +0.2500
- Ramp rate Ramp Rate 0.0050 0.0001 to 0.1000 /s
Var: [Var SETPOINT]
- Minimum value Minimum 0,0 -200.0 to +200.0 %
- Maximum value Maximum 100.0 -200.0 to +200.0 %
Manual: [MANUAL SETPOINT]
- Minimum value Minimum 0.0 0 to 50.0 %
- Maximum value Maximum 150.0 10.0 to 300.0 %
Open Loop: [OPEN LOOP SETPOINT]
- Minimum value Minimum 0.0 0 to 100.0 -- %
- Maximum value Maximum 100.0 10.0 to 100.0 -- %
- Ramp rate Ramp Rate 1.00 0.01 to 100.00 -- %/s
Voltage Droop Compensation
[VDC]
Control
- ID-Nr. Primary net Primary Net ID 1 1 to 31
- ID-Nr. Secondary net Secondary Net ID 2 1 to 31
- Ramp time Ramp Up Time 10.0 0.1 to 60.0 s

INI-File value
Digital I/Os
DIO1: [DIGITAL I/O 1]
- Input Input None Signal name
- Polarity Polarity Normal Normal / Inverted
- Output Output None Signal name
- Direction Direction In In / Out
DI5: [DIGITAL INPUT 5]

INI-File value
Assign analog input to digital signal
DI9 from +AI: [DIGITAL INPUT 9 from +AI]
DI10 from -AI: [DIGITAL INPUT 10 from -AI]
- Input Polarity None Signal name
Signal name:
Digital inputs None None Digital outputs
- DIO1 to 4, Excitation ON Boost - DIO1 to 4
- DI5 to 8, Gen CB Closed Status Field Flashing
(DI9 to14) Parallel with Grid Status System OK
Increase Limit Active
Decrease V/Hz Limit Active
Reset Setpoint SP Limit Reached
Remote SP Enable SP Minimum Reached
PF Enable SP Maximum Reached
Var Enable Operational Limit Active
Manual Enable Min Ie Active
Open Loop Enable Max Ie Active
Synchronize Min PQ Active
VDC Enable Min UM Active
Secondary Net Max UM Active
Reset Alarm Voltage Relay
Standby Close CB Command
RC Fieldbus Block Sync Check
FCB closed Status SW Alarm
Diode Alarm
Diode Trip
SW Alarm or Diode Trip
MODBUS Com Alarm
Close FCB Command
Open FCB Command

INI-File value
Analog Inputs [ANALOG INPUT]
UM Aux: - Minimum value UM Aux Minimum -10.0 -100.0 to +100.0 %
- Maximum value UM Aux Maximum 10.0 -100.0 to +100.0 %
AI1: [ANALOG INPUT 1]
- Low level Uin 0% 0.0 -10.0 to +10.0 V
- High level Uin 100% 10.0 -10.0 to +10.0 V
- Low level Uin 0% 0.0 -10.0 to +10.0 V
- Low level Uin 0% 0.0 -10.0 to +10.0 V
Analog Outputs [ANALOG OUTPUT]
AO1: - Output Output1 None Signal name
AO2: - Output Output2 None Signal name
- Low level Uout1 0% 0.0 -10.0 to +10.0 V
- High level Uout1 100% 10.0 -10.0 to +10.0 V
- Low level Uout2 0% 0.0 -10.0 to +10.0 V
- High level Uout2 100% 10.0 -10.0 to +10.0 V
Ie Range: Output voltage range
- Low level Ie 0% 0.0 0 to 400.0 %
- High level Ie 100% 300.0 0 to 400.0 %
Fbias Range: Offset signal
- Low level Fbias 0% -3.0 -10.0 to +10.0 Hz
- High level Fbias 100% 3.0 -10.0 to +10.0 Hz
Signal name:
Analog inputs AI1 to 3 None None Analog outputs
Auto Remote Setpoint Excitation Current AO1 to 2
PF Remote Setpoint PWM
Var Remote Setpoint Fbias
Manual Remote Setpoint
UM Aux
Reserved2
Cooling Media Temperature
Reserved4
Reserved5

INI-File value
Controller
Auto: [TUNE AUTO]
- Proportional gain Vp Proportional Gain (Vp) 20.0 1.0 to 200.0
- Derivative time constant Tb Derivation Time (Tb) 0.20 0.01 to 5.00 s
- Integral time constant Ta Integration Time (Ta) 4.00 0.01 to 20.00 s
- Reactive current influence Kq Droop (Kq) 0.0 -20.0 to +20.0 %
PF /Var /PQ Limiter: [TUNE PF/Var/PQ LIMITER]
Manual/Ie Limiter: [TUNE MANUAL/Ie LIMITER]
Communication [COMMUNICATION]
ID unit number AVR ID 1 1 to 31
Synchronization [SYNCHRONIZATION]
- Voltage offset UNetoffset 0.0 -30.0 to 30.0 %
- Angle offset Angloffset 0.0 -120.0 to 120.0 deg
- Minimum slip Min Slip 0.00 -1.00 to 0.00 Hz
- Maximum slip Max Slip -0.40 -1.00 to 0.00 Hz
- Maximum voltage difference MaxDeltaU 5.00 0 to 10.00 %
- Maximum delta angle Max Delta Angle 10 0 to 72 deg
- Total CB closing time Tot CB Close Time 90 0 to 630 ms
Diode Monitoring [DIODE MONITORING]
- Nominal exciter frequency f Exc Nominal 50 10 to 400 Hz
- Exciter time constant Tconst Exc 350 1 to 2000 ms
- Diode monitoring active Active FALSE TRUE / FALSE
- Alarm level Alarm Level 5.0 2.0 to 100.0 %
- Alarm delay Alarm Delay 10.0 2.0 to 50.0 s
- Trip level Trip Level 20.0 10.0 to 200.0 %
- Trip delay Trip Delay 0.3 0 to 50.0 s

INI-File value
PSS [PSS]
Active, General activation PSS_SELECT FALSE TRUE / FALSE
Wash out time constants TW1 5.0 0.0 to 30.0 s
PSS gain factor KS1 15.0 0.1 to 50.0 p.u.
Compensation factor for calculation of integral KS2 0.60 0.05 to 5.00 p.u.
of electric power
Signal matching factor KS3 1.00 0.05 to 5.00 p.u.
Lead time constants of conditioning network T1 0.10 0.02 to 6.00 s
Lag time constants of conditioning network T2 0.02 0.02 to 6.00 s
Time constant for integral of electrical power T7 5.00 0.00 to 30.00 s
Ramp tracking filter time constant T8 0.00 0.00 to 2.50 s
Ramp tracking filter time constant T9 0.10 0.00 to 2.50 s
Ramp tracking filter degree M 5 2 to 5
Ramp tracking filter degree N 1 -1 to 4
Upper limit of stabilizing signal PSS max 10.0 0.0 to 25.0 %
Lower limit of stabilizing signal PSS min -10.0 0.0 to -25.0 %
Activation level for PSS functionality P min 5.0 0.0 to 50.0 %
IM Limiter [IM Limiter]
- Limiter high level IMlim_Active FALSE TRUE / FALSE
- Time Multiplier K IMlim_K 1.00 0.01 to 100.00
- Maximum IMlim_Im_th 100.0 0.0 to 100.0 %
TEMP INFLUENCE [TEMP INFLUENCE]
- T1 at Max IM IMlim_T1 50.0 -100.0 to 100.0 °
- Machine current level IMlim_Im_th2 75.0 0.0 to 100.0 %
- T2 at IM th2 IMlim_T2 60.0 -100.0 to 100.0 °
- Machine current level IMlim_Im_th3 50.0 0.0 to 100.0 %
- T3 at IM th3 IMlim_T3 70.0 -100.0 to 100.0 °
- T4 at IM = 0 A IMlim_T4 80.0 -100.0 to 100.0 °
- T1 at Max Continuous Ie IElim_T1 50.0 -100.0 to 100.0 °
- Excitation current level IElim_Ie_th2 75.0 0.0 to 100.0 %
- T2 at Ie th2 IElim_T2 60.0 -100.0 to 100.0 °
- Excitation current level IElim_Ie_th3 50.0 0.0 to 100.0 %
- T3 at Ie th3 IElim_T3 70.0 -100.0 to 100.0 °
- T4 at Ie = 0 A IElim_T4 80.0 -100.0 to 100.0 °

INI-File value
MODBUS [MODBUS]
Slave ID MB Slave 247 1 to 247
Protocol MB_Protocol 0 0 to 1
Bit rate MB_Bitrate 7 3 to 7 and 10 to 12
Character framing MB_ChrFrame 0 0 to 3
Keep-alive time MB_KeepAliveTime 0 0 to 120 s
Keep-alive actions MB_KeepAliveAction 0 0 to 3
MODBUS active MB_Enable FALSE TRUE / FALSE
Answer delay MB_Delay 10 10 to 500 (step of 10) ms
Value Protocol Value Bit rate Value Character framing Value Keep-alive action
0 RTU 0 RESERVED 0 Even 0 none
1 TCP 1 RESERVED 1 Odd 1 Set SW alarm
2 RESERVED 2 none 2 Set fieldbus block
3 115200 3 none 3 Clear fieldbus request
4 57600
5 38400
6 28800
7 19200
8 RESERVED
9
10 9600
11 4800
12 2400
Values have to be saved in the unit.
• Display: Start menu MAIN, Write EEPROM, OK, OK

• CMT 1000:
- Unit: Menu bar CMT 1000 \ File \ Write Parameters to EEPROM
- Harddisk: Menu bar CMT 1000 \ File \ Save Parameter File

REVISION
Rev. Page (P) Description Date
ind. Chapt. (C) (or number of revision) Dept./Init.
A 33 Cross sections 13.12.2004/Mo
78 According to UL specifications
B Includes the Power System Stabilizer parts 03.06.2005/Mo
C Synchronizing, Angle and Voltage Offset 20.01.2006/Mo

IM Limiter
Temperature depending, Ie and IM
MODBUS
FCB Control
CMT 1000, Panel

Bearings
Instructions
For Installation and Operation
Slide Bearings TYPE EF
with self lubrication
RH - EFEEI - E - 11.93
Installation and Operation
RENK AKTIENGESELLSCHAFT
Werk Hannover
Laatzener Straße 21
D - 30539 Hannover
Telephone: (0511) 8601-0
Telefax: (0511) 8601-266
Telex: 922915
Cables: Renkh
All rights reserved. Copy or reproduction without prior permission of RENK Aktiengesellschaft Hannover prohibited.
2 RH-EFEEI-E Version: 20 April, 2006  RENK AG Werk Hannover

EF with self lubrication
Contents
Bearing Coding .................................................................................................................................5
General Drawing Slide Bearing EF with self lubrication ...................................................................7
General Drawing Loose Oil Ring ......................................................................................................9
General Drawing Floating Labyrinth Seal with Seal Carrier ...........................................................11
General Drawing Rigid Labyrinth Seal............................................................................................13
General Drawing Baffle ...................................................................................................................15
General Drawing Dust flinger..........................................................................................................17
1 Considerations for Use ................................................................................................................19
2 Safety Instructions........................................................................................................................20
3 Preparatory Works ........................................................................................................................21
3.1 Tools and equipment.......................................................................................................................21
3.2 Use of lifting equipment ..................................................................................................................21
3.3 Dismantling of the bearing ..............................................................................................................23

3.3.1 Dismantling of the shaft seal - outboard side .................................................................................23
3.3.2 Dismantling of the housing..............................................................................................................24
3.3.3 Dismantling of the shaft seal - machine-side ..................................................................................24
3.4 Cleaning of the bearing ...................................................................................................................25
3.5 Check-up.........................................................................................................................................28
4 Assembly of the Bearing..............................................................................................................26
4.1 Assembly of the machine seal ........................................................................................................26
4.2 Fitting the bottom half of the housing into the machine shield........................................................26
4.3 Fitting in the bottom half of the shell ...............................................................................................27
4.4 Assembly of the shaft seal - machine-side .....................................................................................27
4.5 Installation of the loose oil ring........................................................................................................29
4.6 Fitting in the top half of the shell .....................................................................................................30
4.7 Assembly of the top half of the housing ..........................................................................................31
 RENK AG Werk Hannover RH-EFEEI-E Version: 20 April, 2006 3

5 Assembly of the shaft seals - outboard side .............................................................................32
5.1 Floating labyrinth seal ( Type 10 )...................................................................................................32
5.2 Floating labyrinth seal with dust flinger ( Type 11 ) ........................................................................36
5.3 Floating labyrinth seal with baffle ( Type 12 ) .................................................................................37
5.4 Rigid labyrinth seal ( Type 20 ) .......................................................................................................37
5.5 Rigid labyrinth seal with dust flinger ( Type 21 ) .............................................................................38
5.6 Rigid labyrinth seal with baffle ( Type 22 )......................................................................................39
6 Instructions for Assembly of the Peripheral Equipment ..........................................................40
6.1 Temperature measurement ............................................................................................................40
6.2 Water supply ...................................................................................................................................40
7 Bearing Insulation.........................................................................................................................41
8 Operation .......................................................................................................................................41
8.1 Fill in lubrication oil..........................................................................................................................41
8.2 Trial run ...........................................................................................................................................42
9 Glossary .........................................................................................................................................43

Bearing Coding

➊ ➋ ➌ ➍ ➎ ➏
Type Housing Heat Dissipation Shape of Bore and Type of Thrust part Size - Diameter
Lubrication
E F - flange - mounted N - natural cooling L - plain cylindrical bore with Q - without thrust part 9 80≤D≤100
bearing loose oil ring (non-locating bearing )
W - water cooling 11 100≤D≤125
(finned cooler in oil sump ) B - plain whitemetal lined
shoulders with oil 14 125≤D≤160
grooves (guide bearing)
18 160≤D≤200
K - white metal lined shoulders
with taper land faces 22 200≤D≤250
(integrated)
28 250≤D≤315
Example for bearing coding:
➊ ➋ ➌ ➍ ➎ ➏
E F N L Q 22-200 Type EF slide bearing with flange-mounted housing, natural cooling,
plain cylindrical bore with loose oil ring, non located bearing without thrust part,
size 22, diameter 200.
Shaft seals Type10 - floating labyrinth seal (IP 44)

Type11 - floating labyrinth seal with dust flinger (IP 54)
Type12 - floating labyrinth seal with baffle (IP 55)
Type20 - rigid labyrinth seal ( IP 44)

Type21 - rigid labyrinth seal with dust flinger(IP 54)
Type22 - rigid labyrinth seal with baffle (IP 55)

1 Considerations for Use
The instructions for installation and operation are addressed to qualified technical personnel (fitters,
mechanic installers, mechanical engineers).
Read these instructions carefully before starting assembly.
Slide bearings of type EF are almost universally used in the engineering industry. Therefore it is not
possible to provide detailed information on all possible types and range of applications for these
bearing types. For instance, the position of the connection points for supply and monitoring equipment
is determined by the place of application ( in the following called " installation " ). Please keep ready
the guidelines with the technical documentation before starting assembly and operation of the slide
bearings.
Additional technical documentation with detailed information is supplied in case of special design
bearings. Please contact RENK Export or Domestic Department for supplementary information on
bearings. Please indicate the bearing coding and the full reference number, too.
Following indications should be observed when reading these instructions.
Safety instructions are marked as follows:
Danger!
Warning of dangers for personnel.
Example: Warning of injury
Attention!
Warning of damage for the bearing or installation.
Useful recommandations and additional information are framed.
This is how chapters, instructions or recommandations are marked when referring to a single type or
EFW..
size of a bearing.
Example: Slide bearing type EF with water cooler
- Instruction follows.
• Beginning of an enumeration.
( ) This is how the different parts of a bearing as described in the general drawings( numbers )
are marked in the text.
- Use the enclosed check-list before starting assembly or operation. Copies available on request.
The check list provides the experienced mecanical fitters for RENK bearings with the necessary
instructions for installation and operation.

2 Safety Instructions
Danger!
The maintenance and inspection of the slide bearings should be carried out by:
• persons nominated by the safety representative
• persons correspondingly trained and instructed
• persons with knowledge on appropriate standards, regulations and accident •.
prevention rules
• persons with knowledge on first-aid measures and local rescue centers.
Warning of injury!
Before starting work on the bearing:
- Switch off the installation.
- Make sure the installation is not in operation.
- Never lift or transport machines, etc.by the bearing eye bolts. These are only intended
for assembly and dismantling of the bearing !
Warning of injury!
Do not grab such heavy bearing parts as the bearing housing during assembly or
dismantling works. This could result in bruising or injury to hands !
Attention
All metal parts of a slide bearing consisting of top and bottom part such as the housing, shells, shaft
seals are marked by engraved numbers. Fit together only the parts with the same number.
Attention
In case • the admissible bearing temperature exceeds 15 K
• inadmissible vibrations occur
• unusual noises or odours are noticed
• monitoring equipment triggers alarm
shut down the installation and inform the maintenance personnel in charge.
Attention
Do not operate the bearing below the transition speed values indicated in the bearing calculation, thus
avoiding inadmissible operating conditions, which could lead to damage of the bearing.
20 RH-EFEEI-E Stand: 20 April, 2006  RENK AG Werk Hannover

3 Preparatory Works
3.1 Tools and equipment
- Following tools and equipment are necessary:

• Allan key set
• Wrenching key set
• Open-jawed spanner set
• Feeler gauges ( up 0,05 mm )
•·Caliper gauge
• Emery paper, plain scraper
• Oil rubber
• Lifting equipment
• Permanent sealing compound ( e.g. Curil T )
• Clean cloth
• Oil with the viscosity indicated (see bearing type plate)
• Detergents
• Liquid screw locking compound ( e.g. LOCTITE 242 )
• Liquid sealing compound and Teflon-tape
3.2 Use of lifting equipment
Warning of injury!
Before transport or lifting check if the eye bolts are tight ! Insecure eye bolts could
result in bearing becoming loose.
Before moving the bearing by the eye bolts make sure that the split line screws are
tightened, otherwise the bottom half of the bearing could become detached.
Make sure that the eye bolts are not exposed to bending stress, otherwise the bolts
could break.
Follow exactly the instructions for the use of lifting equipment.
 RENK AG Werk Hannover RH-EFEEI-E Stand: 20 April, 2006 21

- Use lifting equipment for assembly or transport of the following items:
Transport/Assembly of: Use lifting equipment for the following

bearing sizes
Whole bearing unit 9-28
Top half of the housing 14-28
Bottom half of the 11-28

housing
Bearing shells 14-28
- Following steps are to be observed before using the lifting equipment:
Whole bearing unit

- Check if the split line screws are tight (12):
Bearing size 9 11 14 18 22 28
Torque [Nm] 69 69 170 330 570 1150
- Check if the eye bolts (6) are tight.

- Connect the lifting equipment to the eye bolts (6).
Top half of the housing

- Check if the eye bolts (6) are tight.
- Connect the lifting devices to the eye bolts (6).
Bottom half of the housing

- Screw 2 eye bolts (6) with suitable threads tight into the cross-placed opposite tap holes (17).
Bearing size 9 11 14 18 22 28
Tap hole M 12 M 12 M 16 M 20 M 24 M 30
- Connect the lifting equipment to the eye bolts (6).
Bearing shells
- Screw 2 eye bolts or screw hooks with suitable threads tight into the tap holes (9):
Bearing size 14 18 22 28
Tap hole M8 M 12 M 12 M 16
- Connect the lifting equipment to the eye bolts or to the screw hooks.

3.3 Dismantling of the bearing
Attention
Make sure that the work place and the parts to be assembled are clean. Contamination and damages
to the bearing, especially of the running surfaces, have a negative influence on the operating quality
and could lead to premature fatigue.
3.3.1 Dismantling of the shaft seal - outboard side
- Dismantle the shaft seals of the bearing. Proceed according to the sealing type:
Type Floating labyrinth seal with baffle ( Type 12 ):

12
- Unscrew the top half of the baffle (55) and the bottom (57). To do so, loosen the screws (56).
- Further proceed as in the case of type 10 and 11seal.
Type Floating labyrinth seal (Type 10)

10 Floating labyrinth seal with dust flinger (Type 11)
Type - Loosen and remove all screws (44).
11 - Simultaneously take away in axial direction both top half (37) and bottom half (40) of the seal carrier
from the housing.
- Lift off the top half of the seal carrier (37) and take out the floating labyrinth seal from the bottom half
of the seal carrier (40).
- Remove the protective cardboard (transport protection) from the floating labyrinth seal.
Proceed as indicated for sizes • 9-11
•14-28
Size - Take hold of the floating labyrinth seal with both hands.Press out the protective cardboard with both
9 -11 thumbs.
Size - Take both halves of the seal (41)(42) by the split line.Pull both halves apart, till you can press out the
14-18 protective cardboard. Remove carefully by pressing along the edge of the split line.
Warning of injury!
During dismantling of the floating labyrinth seal hold on tight to the spanned hook spring
(38) which otherwise could bounce and lead to injury.
- Take both seal halves (41),(42) and pull them apart by approximately 20 mm.
- Open the hook spring (38).
Type Rigid labyrinth seal with baffle (type 22)

22
- Unscrew the top and bottom half (55),(57) of the baffle, by untightening the screws (56).
- Further proceed as in the case of types 20 and 21.

Type Rigid labyrinth seal (type 20)

20 Rigid labyrinth seal with dust flinger (type 21)
Type - Untighten all screws (49) and remove them.
21 - Simultaneously remove in axial direction both top and bottom (48) ,(52) halves of the rigid labyrinth
seal.
- Remove the split line screws (50).
- Separate the top half of the rigid labyrinth seal (48) from the bottom half (52) and take out the
protective cardboard (for safe transport).
3.3.2 Dismantling of the housing
- Unscrew the split line screws (12) and lift the top half of the housing (1).
- Take out both top (11) and bottom (13) halves of the shell from the bottom half (21) of the housing.
Attention!
Do not damage the thrust and radial running surfaces!
- Unscrew the split line screws (19) and separate top and bottom half of the shell (11), (13) without
using any tools or other devices.
Attention!
If the bottom half of the shell (13) is provided with metal tabs (28) do not remove them.They regulate
the oil level in the oil pockets.
EFW..
The oil cooler (26) is already assembled and does not have to be removed for cleaning purposes.
3.3.3 Dismantling of the shaft seal - machine-side
The machine side seal is of Type 10, floating labyrinth seal.

- Remove the floating labyrinth seal from the bottom half of the housing.
- Notice the anti-rotation pin at the split line of the bottom half of the housing.
- Remove the protective cardboard (transport protection) from the floating labyrinth seal.
Proceed as indicated for sizes • 9-11
•14-28
Size - Take hold of the floating labyrinth seal with both hands.Press out the protective cardboard with both
9 -11 thumbs.
Size - Take both halves of the seal (41)(42) by the split line.Pull both halves apart, till you can press out the
14-18 protective cardboard. Remove carefully by pressing along the edge of the split line.
Warning of injury!
During dismantling of the floating labyrinth seal hold on tight to the spanned hook spring
(38) which otherwise could bounce and lead to injury.

- Take both seal halves (41),(42) and pull them apart by approximately 20 mm.
- Open the hook spring (38).
3.4 Cleaning of the bearing
Attention!
Use only non-aggressive detergents, such as for instance:
• VALVOLINE 150.
• Alcaline cleaning compounds (pH-value 6 to 9, short reaction time).
Warning of injury!
Please observe the instructions for the use of the detergents.
Attention!
Never use cleaning wool or fibrous cloth. Residues of such materials left in the bearing could lead to
excessive temperatures.
- Clean the following parts thoroughly, to remove all residues of preservation :

• inside the top half of the housing (1)
• inside the bottom half of the housing (21)
• all plain parts of the top and bottom half of the housing (1),(21)
• top half of the shell (11)
• bottom half of the shell (13)
• sealing surfaces of the top (37) and bottom (40) half of the seal carrier or of the rigid labyrinth seal
• loose oil ring (33).
3.5 Check-up
- Please check if there is any visible damage.Check the split line and the running surfaces in
particular.
The loose oil ring (33) should show absolutely no burrs or have no shoulders.
Insulated - Check the insulating layer of the spherical seatings (14).

Bearings
- If necessary, change the damaged parts.

4 Assembly of the Bearing
Attention!
Remove all impurities or other objects such as screws, nuts, etc. from inside the bearing.If left inside
they could lead to damage to the bearing. Cover up the opened bearing during breaks.
Attention!
Carry out all assembly operations without making use of force.
Attention!
Use a liquid screw locking compound (e.g. LOCTITE 242) for all housing, split line and flange screws.
4.1 Assembly of the the machine seal
Before assembly of the bearing screw the split and non-split machine seal (10) into the machine
shield. The non-split machine seal must be assembled before starting the assembly of the shaft.
- Place the machine seal with the recess onto the machine shield.
- In the case of a split machine seal insert the split line screws and tighten them hand tight.
- Tighten the screws (7) by using the following torque values:
Bearing size 9 11 14 18 22 28
Tap hole M6 M6 M6 M8 M8 M8
Torque [Nm] 8 8 8 20 20 20
4.2 Fitting the bottom half of the housing into the machine shield
Attention!
The lifting equipment should not come in touch with the seal and running surfaces of the shaft.
- Lift the shaft high enough to have place for the assembly operations.
- Protect the shaft against unintended movement.
- Place the bottom half of the housing with the recess (16) into the spigot fit of the machine shield.
- Tighten the flange screws by using the following torque values.
- Use only 8.8 quality screws.
Bearing size 9 11 14 18 22 28
Suitabel flange screws M 10 M 12 M 16 M 20 M 24 M 30
Torque [Nm] for µ tot (lightly oiled) 69 69 170 330 570 1150

4.3 Fitting in the bottom half of the shell
- Apply some lubricant on the spherical seating (14) in the bottom half of the housing (21) and on the
running surfaces of the shaft.Use the same type of lubricant as indicated for bearing operation ( see
type plate ).
- Place the bottom half of the shell (13) on the running surface of the shaft. Turn the bottom half of the
shell (13) into the bottom half of the housing (21) with the split line surfaces of both halves in true
alignment.
In case the bottom half of the shell doesn`t turn in easily, check the position of the shaft and the
alignment of the bearing housing
EF..B, Attention!
EF..K These operations should be carried out most carefully. The thrust parts of the bottom shell should
not be damaged.
- Lower down the shaft till it sits on the bottom half of the shell (13).
4.4 Assembly of the shaft seal - machine-side
The machine-side shaft seal is standard-wise a floating labyrinth seal. The integrated seal groove is in
the top and bottom halves of the housing.
Warning of injury!
During assembly hold the hook spring ends securely to avoid them suddenly releasing
and causing possible injury !
Check the movement of the floating labyrinth seal on the shaft in the seal area outside the housing.
- Put the hook spring (38) around the shaft and hook both ends into each other.
- Put both halves of the seal (41),(42) in their place on the shaft.
- Put the hook spring (38) into the spring groove (39).
- Turn the floating labyrinth seal on the shaft.
Attention!
The floating labyrinth seal should turn easily on the shaft. A jammed seal could lead to overheating
during operation and even to shaft wear.
If the floating labyrinth seal jams,
- dismantle the shaft
- remove the worn parts of the seal carefully, by using emery paper or a plain scraper.
- Dismantle the floating labyrinth seal.

- Apply Curil T on the guide surfaces of the integrated seal groove in the bottom half of the housing.

21
Illustration 1: Application of Curil T on the integrated seal groove
- Apply a uniform layer of Curil T on the guide surfaces and on the split line surfaces of both halves of
the seal (41), (42).
41
Illustration 2: Application of Curil T on the floating labyrinth seal
Please observe the instructions for the use of Curil T.
- Place the bottom half of the seal (41)) with the labyrinths onto the shaft.
- The oil return holes at the bearing side must be opened.
- Turn the seal in opposite direction from the anti-rotation pin into the groove of the housing until the
split lines of the bottom half of the housing and the bottom half of the seal match each other.
- Remove the rests of Curil T.
- Push the spring hook into the integrated seal groove between the bottom half of the housing and the
seal until both ends jut out from the split line.
- Place the top half of the seal with the cam facing the inside of the bearing on the bottom half of the
seal.
- Stretch the hook spring till both ends can be hooked.

4.5 Installation of the loose oil ring
- Open both split lines of the loose oil ring (33) by untightening and removing the screws (36).
Separate both halves of the loose oil ring (33) carefully without using any tools or other devices.
I II
33
33 33
36
Illustration 3: Opening of the loose oil ring
- Place both halves of the loose oil ring into the shell groove encircling the shaft.Press the positioning
pin (34) of each split line into the corresponding hole (35).
- Adjust both halves of the loose oil ring till the split lines match each other.
21
34
33
33 13
Illustration 4: Installation of the loose oil ring

Bearing size 9 11 14 18 22 28
Torque [Nm] 1,4 1,4 1,4 2,7 2,7 2,7
4.6 Fitting in the top half of the shell
- Apply some lubricant on the running surfaces of the shaft. Use the same type of lubricant as
indicated for bearing operation (see type plate).
- Check if the engraved number (15) on the bottom half of the shell corresponds with the engraved
number (15) on the top half of the shell.
- Place the top half of the shell (11) on the shaft; both engraved numbers(15) should be on one side.
Attention!
An incorrectly placed shell could jam the shaft thus leading to the damage of both shaft and bearing.
EF..B, Attention!
EF..K Place the top half of the shell carefully on the shaft. The thrust parts of the top half of the shell should
not be damaged.
- Tighten up the split line screw (19) by using the following torque values:
Bearing size 9 11 14 18 22 28
Torque [Nm] 8 8 20 69 69 170
- Check the split line of the bearing shell by using a feeler gauge. The split line gap should be less
than 0,05 mm. If the split line is greater than this, dismantle both top (11) and bottom (13) halves of
the shell. Rework the split line surfaces of the top (11) and bottom (13) half of the shell with an oil
rubber.
- Check the mobility of the loose oil ring (33).
Marine A guide bush in the top half of the shell secures the function of the loose oil ring.
bearings - Check the mobility of the loose oil ring (33) in the guide bush.

4.7 Assembly of the top half of the housing
- Check the true alignment of the split lines of the shell (11),(13) and bottom (21) half of the housing.
The positioning pin (3) in the top half of the housing fits in the corresponding positioning pin hole (2) in
the shell.
- Check if the engraved numbers (20) on the top and bottom halves of the housing correspond.
- Clean the split line surfaces of the top and bottom halves of the housing.
- Apply Curil°T over the whole surface of the split line of the bottom half (21) of the housing.
- Place the top half of the housing carefully into the machine shield, without touching the seals or the
bearing shell.
- Lower the top half of the housing (1) vertically on the bottom half of the housing (21). Lower the top
half of the housing (1) till the split line of the housing is not visible any more.
- Gently hit the bottom half of the housing (21) with a nylon hammer, thus ensuring the alignment of
the spherical seating.
- Insert the split line screws (12). Tighten them hand-tight.
- Insert the flange screws (8). Tighten them by using the following torque values:
Bearing size 9 11 14 18 22 28
Torque [Nm] 69 69 170 330 570 1150
- Insert the split line screws (12). Tighten them crosswise by using the same torque values.

5 Assembly of the Seals - Outboard Side
- Assemble the outboard side seals.

Proceed according to the seal type used.
• Floating labyrinth seal (Type 10) Chapter 5.1

• Floating labyrinth seal with dust flinger (Type 11) Chapter 5.2
• Floating labyrinth seal with baffle (Type 12) Chapter 5.3
• Rigid labyrinth seal (Type 20) Chapter 5.4

• Rigid labyrinth seal with dust flinger (Type 21) Chapter 5.5
• Rigid labyrinth seal with baffle (Type 22) Chapter 5.6
Type 5.1 Floating labyrinth seal (Type 10)

10
Warning of injury!
During assembly hold the hook spring ends securely to avoid them suddenly releasing
and causing possible injury !
Check the movement of the floating labyrinth seal on the shaft.

- Put the hook spring (38) around the shaft and hook both ends into each other.
- Put both halves of the seal (41),(42) in their place on the shaft.
- Put the hook spring (38) into the spring groove (39).
- Turn the floating labyrinth seal on the shaft.
Attention!
The floating labyrinth seal should turn easily on the shaft. A jammed seal could lead to overheating
during operation and even to shaft wear.
If the floating labyrinth seal jams,
- dismantle the shaft
- remove the worn parts of the seal carefully, by using emery paper or a plain scraper.
- Dismantle the floating labyrinth seal.

- Apply a uniform layer of Curil T on the guide surfaces and on the split line surfaces of both halves of
the seal (41), (42).

41
Illustration 5: Application of Curil T on the floating labyrinth seal
- Press the bottom half of the seal (41) against the shaft.
- Place the top half of the seal (42) on the shaft and align both halves of the seal to each other.
- Place the hook spring (38) into the spring groove (39) and stretch until both ends can be hooked.
43 42 1
38 41 21
Illustration 6: Assembly of the floating labyrinth seal
- Place in true alignment the split line of the floating labyrinth seal and the split line of the seal carrier.
- Check that both engraved numbers (45) and(47) on top and bottom halves of the seal
carrier(37),(40) correspond.

- Clean the following parts: • the seal surfaces of the top (37) and bottom (40) half of
• the seal carrier (the groove of the floating labyrinth seal, the
flange surfaces)
• the split line surfaces of the top (37) and bottom half (40)
of the seal carrier
• the flange surfaces of the housing.
- Apply a uniform layer of Curil T on:

• the lateral surfaces of the groove at the top (37) and bottom half (40) of the seal carrier
• the flange surfaces of the top (37) and bottom (40) half of the seal carrier
• the split line surfaces of the bottom half of the seal carrier (40).
40
Ilustration 7: Application of CurilT on the seal carrier

- Place the top half of the seal carrier (37) on the top half of the seal (42). Press the bottom half (40) of
the seal carrier against it. Push the shaft seal completely into the housing.
37
43
42
Illustration 8 Assembly of the seal carrier
- Place in true alignment the split lines of the seal carrier and the housing.
- Tighten up the screws (44) by using the following torque values:
Bearing size 9 11 14 18 22 28
Torque [Nm] 8 8 8 20 20 20

Type11
5.2 Floating labyrinth seal with dust flinger (Type 11)
- Assemble the floating labyrinth seal with dust flinger as described in Chapter 5.1, Floating labyrinth
seal type 10.
- Place both halves of the dust flinger (58) in front of the shaft seal around the shaft.Loosely screw in
the split line screws (59).
58 37
e 46
Illustration 9: Clearance between dust flinger and seal carrier
EF..Q - Push the dust flinger (58) into the groove (46) of the seal carrier.
- Set the clearance "e" at the following figure around the whole unit:
maximum longitudinal extension of the shaft in operation + 1 mm
(Parameters indicated in the Technical Documentation of the Installation).
- Tighten up both screws (59) at the split line by using the following torque values:
Seal diameter [mm] 80-140 >140
Torque [Nm] 7 18
EF..B, - Push the dust flinger (58) into the groove (46) of the seal carrier.
EF..K - Set the clearance "e"at 1 mm around the whole unit.
- Tighten both screws (59) at the split line by using the following torque values:
Torque [Nm] 7 18

Type 5.3 Floating labyrinth seal with baffle ( Type 12)

12
- Assemble the floating labyrinth seal with baffle as described in Chapter 5.1, type10.
- Apply a uniform layer of Curil T on the flange surfaces of the top half (55) and bottom half (57) of the
baffle.
- Screw • the top half of the baffle (55) onto top half of the seal carrier (37)
• the bottom half of the baffle (57) onto bottom half of the seal carrier (40).
Torque [Nm] 4 10
Type 5.4 Rigid labyrinth seal (Type 20)

20
- Check if the engraved numbers (53) and (54) on the bottom half (52) and top half (48) of the rigid
labyrinth seal correspond.
- Clean • the flange surfaces of the top half (48) and bottom half (52) of the rigid
labyrinth seal
• the split line surfaces of the top half (48) and bottom half (52) of the rigid
labyrinth seal
• the flange surfaces of the housing.
- Apply a uniform layer of Curil T on the following parts:
• the flange surfaces of the top (48) and bottom half (52) of the rigid labyrinth seal
• the split lines of the bottom half (52) of the rigid labyrinth seal.
52
Illustration 10: Application of Curil T on the rigid labyrinth seal
- Place the top half (48) of the rigid labyrinth seal on the shaft and press slightly the bottom half (52) of
the rigid labyrinth seal from below against it. Lightly push the rigid labyrinth seal completely into the
housing.
- Tighten the split line screws (50).
- Place in parallel alignment the split line of the rigid labyrinth seal and the split line of the housing.
Press the rigid labyrinth seal slightly from below against the shaft. Adjust the rigid labyrinth seal in

such a way that the clearance "f" between the shaft and the rigid labyrinth seal at both split lines has
the same figure.
1 48
f f
21 52
Illustration 11: Alignment of the rigid labyrinth seal
Bearing size 9 11 14 18 22 28
Torque [Nm] 8 8 8 20 20 20
5.5 Rigid labyrinth seal with dust flinger (Type 21)
Type - Assemble the rigid labyrinth seal with dust flinger as described in Chapter 5.4, type 20.
21 - Place both halves of the dust flinger (58) round the shaft, in front of the rigid labyrinth seal. Loosen
both screws (59) of the split line.

58 48
e
51
Illustration 12: Clearance between dust flinger and rigid labyrinth seal
EF..Q - Push the dust flinger (58) into the groove (51) of the rigid labyrinth seal.
- Set the clearance "e" at the following figure around the whole unit.
maximum longitudinal extension of the shaft in operation + 1 mm
(Parameters are indicated in the Technical Documentation of the Installation).

- Tighten both screws (59) at the split line with the following torque values:
Seal diameter[mm] 80-140 >140
Torque [Nm] 7 18
EF..B,
- Push the dust flinger (58) into the groove (51) of the rigid labyrinth seal.
EF..K
- Set the clearance "e" at 1 mm around the whole unit.
- Tighten both screws (59) at the split line by using the following torque values:
Torque [Nm] 7 18
Type 5.6 Rigid labyrinth seal with baffle (Type 22)

22
- Assemble the rigid seal with baffle as described in Chapter 5.4, type 20.
- Apply a uniform layer of Curil T on the flange surfaces of the top half (55) and bottom half (57) of the
baffle.
- Tighten • the top half of the baffle (55) on the top half (48) of the rigid labyrinth
seal
• the bottom half of the baffle (57) on the bottom half (52) of the rigid
labyrinth seal.
Torque [Nm] 4 10

6 Instructions for Assembly of Peripheral Equipment
6.1 Temperature measurement
- Fix suitable feeler gauges:

• into one of the connection holes (22) for temperature measurements of the journal parts
• into one of the connection holes (24) for temperature measurements of the oil sump
Proceed as follows:
- Take out the screw plugs from the connection holes.
- Place the thermo sensor into the bore by using Teflon tape or sealing compound.
- Connect the thermo sensor at the temperature monitoring equipment of the installation(see the
Technical Documentation of the Installation for connecting and adjustement).
EFW.. 6.2 Water supply
Following requirements should be observed before connecting the oil cooler (26):
• water velocity of maximum 1,5 m/s in the cooling water inlet
• water pressure of maximum 5 bar
• adjusting tap on inlet
• outlet of cooling water under no pressure.
The direction of the cooling water passage in the oil cooler (26) is arbitrary.

7 Bearing Insulation
These bearings are delivered insulated. The electrical insulation is guaranteed by:
• plastic coating of the spherical seatings (14)
• shaft seals out of non-conducting materials
• insulated positioning pin (3)
• insulated screwed connections for thermometers.
- Mark the insulated bearing with the delivered plate " Insulated bearing shells".Mount the plate at a
visible place by using 2 grooved drive studs.
8 Operation
8.1 Fill up lubrication oil
Attention!
Make sure that no impurities get into the bearing.
- Tighten all screw plugs in the connection holes (22), (24), (27) with the necessary torque values:
Screw plug threads G 3/8 G 1/2 G 3/4 G1 G 1 1/4 G 1 1/2 G2 G 2 1/2
Torque [Nm] 30 40 60 110 160 230 320 500
- Check if:
• the top sight glass (5) is tight, the screws should be hand-tight.
• Oil sight glass (23) is tight, the screws should be hand-tight.
In the case thermo sensors or / and oil sump thermometers are used:
- Check if they are tight (according to the manufacturer's instructions).
- Remove the screw plugs from the oil filler hole (4).
- Use a lubricant with the viscosity indicated on the bearing type plate. Fill the lubricant through the oil
filler hole (4) up to the middle point of the oil sight glass (23).
The oil level limits are as follows:

minimum oil level: bottom of the oil sight glass
maximum oil level: top of the oil sight glass
Attention!
• Not enough lubricant leads to temperature rises and thus to damages to the bearing.
• Too much lubricant leads to leakages. In the case of bearings with lubrication by loose oil
ring too much lubricant could brake the oil rings considerably, thus leading to damages to
the bearing.

- Tighten the screw plug into the oil filler hole (4) by using the following torque values:
Bearing size 9 11 14 18 22 28
Torque [Nm] 30 30 30 40 60 60
- Remove the protective layer from the top sight glass (4).
8.2 Trial runFehler! Textmarke nicht definiert.
- Before the trial run, check the following:

• oil level (see Chapter 8.1)
• if the temperature monitoring equipment works
EFW.. • if the water cooling installation works.
The bearing is ready for operation.
- Supervise the bearing during the trial run (5-10 operating hours).Pay special attention to:
• oil level (see Chapter 8.1)
• bearing temperature
• sliding noises of the shaft seals
• tightness
• occurrence of inadmissible vibrations.
Attention!
If the bearing temperature exceeds the calculated value of 15 K(see Bearing calculation) stop the
installation immediately. Carry out an inspection of the bearing as described under Instructions for
Service and Inspection of the Slide Bearings Type EF with self lubrication.

9 Glossary
Baffle With bearing types 10 and 20 the baffles are assembled externally in front of the shaft seals.
The baffle, made of reinforced polyamide, protects the bearing from dust and water.
Rigid labyrinth seal The rigid labyrinth seal (type 20) is used with slide bearings type E with high oil throughput.It
corresponds to the protective system IP44 and is made of an aluminium alloy.
The rigid labyrinth seal is built of 2 halves, flanged at the bearing housing.The labyrinths that
wipe out the lubricant are arranged into two groups.The first two labyrinths , lying inside keep
back most of the lubricant. Five further labyrinths protect the bearing from outside.They
prevent the lubricant overflow and the penetration of impurities.The overflow lubricant is
collected into a chamber lying between the both groups of labyrinths.Through the return
bores the lubricant flows back into the bearing.
Spherical seating The spherical seating is a special form to provide the alignment of the shell in the
housing.The shell is placed on two spherical seatings. The advantages of the spherical
seating are:
• easy assembly
• good heat transfer from the shells to the housing
• suitable for such applications where high thrust or radial forces occur
Dust flinger In the case of bearing types 10 and 20 a light alloy ring is clamped on the shaft in front of the
shaft.This ring fits into a groove in the seal carrier or the rigid labyrinth seal, thus building a
labyrinth. The labyrinth protects the shaft exit against low pressure that could otherwise "
absorb " the lubricant. Low pressure occurs for instance in the case of rotating discs, such as
couplings or cooling discs.
Floating labyrinth The floating labyrinth seal (type 10) in the seal carrier is used as a shaft seal in the case of
seal bearings of type E operating under normal conditions. It prevents the lubricant and lubricant
mist coming out and the penetration of impurities. The floating seal has a high capacity of
resistance to wear. It is made of a high-performance, high temperature stability and
electrically insulated plastic material.The floating seal consists of two halves held together by
a spring. Both ends of the spring are hooked into one another, that is why this part is also
called hook spring. In the case of slide bearings of type EF the floating seal is mounted into a
two-piece seal carrier. The seal carrier permits radial movements of up to 1 mm. The seal is
thus insensitive to shaft movement or deflexion. The sealing effect is produced by the
labyrinths wiping off the lubricant from the shaft. Through the return holes the lubricant flows
back into the bearing.
Machine seal In the case of the flange-mounted bearings the machine seal prevents leakages at the
machine-side seal in reducing the positive and negative pressure in the machine. The
pressure equalizing cavity between the machine seal and the bearing housing must always
be connected to pressureless atmosphere. The gap between shaft and machine seals is
limiting the sealing effect. For higher requirements the seal can be provided with hamp
packing or a gap seal. These types of seals are placed into the grooves of the machine seal.

Empfehlung für synthetische Recommendation for Synthetic Lu-
Schmierstoffe für Renk Gleitlager bricants for Renk Sleeve Bearings
Beide Gleitlager der Maschine sind für synthe-
tische Schmierstoffe geeignet. Both sleeve bearings of the machine are ordered
for synthetic lubricants.
Gleitlager werden ab Werk ohne Ölfüllung ausge-
liefert und sind mit Korrosionsschutz versehen. Sleeve bearings are delivered without oil filling
Korrosionsschutz braucht vor Inbetriebnahme and are protected against corrosion by the manu-
nicht entfernt zu werden. facturer.
There is no need to remove the protective coat
before commissioning.
Schmierstoffe
Lubricants
Als Schmierstoff dürfen nur Maschinenöle ent-
sprechend der nachfolgenden Schmierstoffliste For lubrication only lubricants according to the
verwendet werden. following list can be used.
Es ist unbedingt auf richtige Vis-

kosität, Ölmenge und Öldruck ge- It is essential to pay attention to
mäß Maßzeichnung zu achten. the viscosity, oil quantity and oil
pressure according to the data on
the dimensional drawing.
Die Lager sollten vor Inbetriebnahme bis etwa
Mitte des Schauglas mit Öl gefüllt sein. The bearings should be filled with oil, up to about
half of sight glass prior to commissioning.
Schmierstoffempfehlung:
Recommendation:
Shell Corena AS 46 Shell Corena AS 46
Klueber Summit SH 46 Klueber Summit SH 46
Esso and Mobil Lubricants, Hamburg Esso and Mobil Lubricants, Hamburg
www.mobil-oil.com www.mobil-oil.com
AvK Deutschland GmbH & Co. KG AvK Deutschland GmbH & Co. KG
Bunsenstr. 17 Dreieich branch
85053 INGOLSTADT Benzstr. 47-49
GERMANY 63303 Dreieich
www.newage-avkseg.com Phone: +49(0)841-792-0 GERMANY
infoavkin@newage-avkseg.com Fax: +49(0)841-792-250 Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40
Spare Parts
Ersatzteile: 0.2.0 Spare Parts: 0.2.0
1 Dichtungsträger Seal Carrier

2 Labyrinthdichtung mit Wurmfeder (außen) Labyrith seal with Garterspring (outside)
3 Ölablauf Oil Outlet
4 Gehäuse Unterteil Housing Lower Part
5 Gehäuse Oberteil Housing Upper Part
6 Ringschraube Ring Bolt
7 Ölschauglas (Gehäuse Oberteil) Oil inspection glass (upper part of housing)
8 Gleitlagerschalen Sleeve bearing Shells
9 Schmierring Lubrication Ring
10 Labyrinthdichtung mit Wurmfeder (innen) Labyrinth seal with Garterspring (inside)
11 PT 100 PT 100
12 Ölschauglas (Gehäuse Unterteil) Oil inspection glass (lower part of housing)
13 Sichtthermometer Thermometer
14 Kühlschlange Cooling Coil
15 Ölablassschraube Oil drain plug
Fax: +49(0)6103-5039-40
1 Gleitlager AS Sleeve Bearing DS

2 Lagerschild AS Endshield DS
3 Luftblende AS Air baffle DS
4 Maschinendichtung AS Seal Retainer DS
5 Statorgehäuse Stator housing
6 Maschinendichtung BS Seal Retainer NDS
7 Erreger-Stator Exciter Stator
8 Lagerschild BS Endshield NDS
9 Gleitlager BS Sleeve Bearing NDS
10 Dichtungsträger Seal Carrier
11 Luftblende für Hilfserreger Air baffle for aux. exciter
12 Hilfserregergehäuse Aux. Exciter
13 Hilfserregerstator Aux. exciter stator
14 Montagedeckel für Hilfserreger Service Cover
15 PT100 B-Lagerschild PT100 Endshield NDS
16 Stillstandsheizung Anti Condensation Heater
17 PT100 A-Lagerschild PT100 Endshield DS
18 Bürstenhalter für Rotorerdung Brush holder for Rotor Grounding
19 Kohlen für Rotorerdung Brushes for Rotor Grounding
Fax: +49(0)6103-5039-40
1 Ventilator Fan
2 Ventilatorbuchse Fan hub
3 Passfeder für Wellenstummel Key for shaft end
4 Passfeder für Ventilatorbuchse Key for fan hub
5 Rotor komplett Rotor complete
6 Spulenhalter Coil holder
7 Passfeder für Erreger-Rotor Key for Exciter Rotor
8 Passfeder für Hilfserreger-Rotor-Buchse Key for Auxiliary-Exciter Rotor-Bushing
9 Erreger-Rotor Exciter Rotor
10 Wellensicherungsring für Erreger-Rotor Circlip for Exciter Rotor
11 Hilfserreger-Rotor Auxiliary Exciter Rotor
12 Wellensicherungsring für Hilfserreger-Rotor Circlip for Auxiliary Exciter Rotor
13 Passfeder für Hilfserreger-Rotor Key for Aux. Exciter Rotor
14 Buchse für Hilfserreger-Rotor Bushing for Aux. Exciter Rotor
15 Gleichrichterträger Rectifier Carrier
16 Rotierender Gleichrichter Rotating Rectifier
17 Überspannungs-Ableiter Overvoltage Arrestor
18 Wellensicherungsring für Hilfserreger-Rotor- Circlip for Aux. Exciter Rotor Bushing
Buchse
infoav kin@newage-avkseg.com Fax: +49(0)841-792-250 Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40
Ersatzteile: 3.0.0.1 ms Spare Parts: 3.0.0.1 ms
1 Klemmenkasten Unterteil Terminal Box Lower Part

2 Stromwandler Current transformer
3 Kupferschiene Wandleranschluß Copper Bar Transformer Terminal
4 Kupferschiene Sternpunkt Copper Bar Star Point
5 Kupferschiene U, V, W Copper Bar U, V, W
6 Isolator Insulator
7 Statik Wandler Static Transformer
8 Klemmkasten-Deckel Terminal Box Cover
9 Abschlussplatte Endcover Plate
10 Muffe Oberteil Bushing upper part
11 Muffe Unterteil Bushing Lower Part
12 Anpassungstrafo Potential Transformer
13 Schutzschalter für Anpassungstrafo Security Switch for Potential Transformer
www.newage-avkseg.com Phone: +49(0)841-792-0 GERMAN Y
infoav kin@newage-avkseg.com Fax: +49(0)841-792-250 Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40
Ersatzteile: 4.0.0 oRT Spare Parts: 4.0.0 oRT
1 Hilfsklemmenkasten Auxiliary Terminal Box

2 Deckel für Hilfsklemmenkasten Cover Auxiliary Terminal Box
3 Reihenklemmen Terminals in a Row
4 U-Schiene U-Bar
5 Abschlussplatte Gland Plate
Fax: +49(0)6103-5039-40
Ersatzteile: 6.0 obi Spare Parts: 6.0 obi
1 Kupferschiene Copper Bar

5 Überspannungsableiter Over Voltage arrestor
6 Kabelbrücke Cable link
7 Rotierende Gleichrichter Rotating Rectifier
8 Halterung Holding device
9 Gleichrichterträger Rectifier Carrier
Fax: +49(0)6103-5039-40
Technical Data
page 1 Standard Specification
date: 15.03.2006
Generator for Wärtsilä engine
file: W20V34-50Hz-11kV-10913kVA.doc
W20V34SG
.
Type DIG 167 f/8
Rated data:
Output/kVA 10.913
Power factor cos ϕ 0,8
Rated voltage/V 11.000
Rated current/A 573
Frequency/Hz 50
Rated speed/rpm 750
Rules and regulations:

Rules IEC 60034
R.I.S. deg.acc. to VDE 0875 N
Ambient air temp./°C 50
Site altitude/m a.s.l. 1.000
Insulation class F
Temperature rise acc. to class F
Duty type: S1, continuous operation
Electrical data and characteristics:

Circuit diagram no.: K850.3.104
Rated voltage operation range: Between 95 ... 105 % of rated voltage.
Voltage adjustment range +/-5 % of rated voltage for continuous operation
+/- 10 % of rated voltage for short time only resp. for
synchronization
Dynamic voltage variation TVD = - 25 % at sudden full load application at rated PF
TVR = + 28 % at sudden full load shedding at rated PF
Parallel operation Alternator suitable for parallel operation, both with mains and
other alternators. Damper cage and droop transformer are
built-in.
Overload 10 % for 1 h, within 6 hours.
or acc. to IEC 60034, i.e. 50 % for 30 sec.
(see attached overload curve)
Voltage wave form line-line no load: Deviation less than 5 % (IEC 60034)
Single harmonic Less than 2,5 %
Efficiency at 1/4 2/4 3/4 4/4 5/4 load

• cos ϕ = 0,8 95,2 96,9 97,3 97,3 97,3 %
• cos ϕ = 0,9 95,3 97,1 97,6 97,6 97,6 %
• cos ϕ = 1 95,4 97,3 97,8 98,0 98,0 %
Reactances:
• synchronous xd = 198 % (unsaturated)
• transient xd' = 32,5 % (saturated)
• subtransient xd'' = 18,0 % (saturated)
• inverse x2 = 18,9 % (unsaturated)
• zero sequence xo = 5,4 % (unsaturated)
• quadrature axis synchronous xq = 99 % (unsaturated)
• quadrature axis subtransient xq" = 19,8 % (saturated)
• leakage reactance x1s = 14,4 %
• Rated impedance ZN = 11,09 Ω
• short circuit ratio Kc = 0,55 p.u.
date: 15.03.2006
W20V34SG
.
Resistances:
• Stator winding ra (20°C) = 0,0049 p.u. (20°C)
• Main field rf (20°C) = 0,650 Ω (20°C)
Time constants:
• transient no-load Tdo' = 4,00 s
• subtransient no load Tdo” = 36 ms
• transient short circuit Td ' = 660 ms
• subtransient short circuit Td'' = 20 ms
• quadrature axis subtransient Tq " = 63 ms
• quadrature axis subtr. no load Tq0" = 200 ms
• anchor / DC Ta = 140 ms
• exciter machine Te = 340 ms
Short circuit data:

• Sustained 3-phase S.S.C. 1,72 kA for 5 s
• Max. peak current 3-phase: 8,10 kA
• Initial short circuit 3-phase 3,18 kA
• Initial SC torque 2-phase: 1003 kNm
• Initial SC torque 3-phase: 772 kNm
Exciter data:
• Field resistance rf (20°C) = 10,3 Ω (20°C)
• Current + voltage no load: if0 = 1,5 A / uf0 = 18 V
• Current + voltage rated load: ifN = 4,4 A / ufN = 52 V
Construction:
• The generators consist of a primary internal pole machine and an external pole exciter.
For power supply to the automatic voltage regulator, the alternators are equipped with an auxiliary
winding.
• Stator:
A welded design is used for the stator housing. The stator core pack consists of hydraulically
pressed, low-loss dynamo laminations. It is pressed together with the housing via pressure plates
to form a compact unit. This ensures a stiff construction appropriate for the special operating
conditions for Diesel generating sets.
The stator winding is insulated in accordance with insulation class F acc. to EN 60034.
The winding heads and wirings are supported by suitable fastening elements and firmly linked
together by mechanical means to guard against electrodynamic loads caused by current forces.
• Rotor:
The rotor consists of the shaft and the main revolving field.
The main revolving field in salient pole design consists of hydraulically pressed lamination sheets
or of steel plates. A damper cage is installed as standard.
The main rotor windings are made of flat copper and are protected against centrifugal forces by
suitable components.
The rotor winding is insulated in acccordance with insulation class F acc. to EN 60034
As standard the rotor is dynamically balanced with half key acc. to EN 60034.
• Bearing plates:
Bearing plates are welded. The alternator feet are integrated in the bearing end housings.
Design details:
Design B 20 / IM1101
Outline drawing no.: AZ 12749 C
Rotor drawing no.: 87485.1 C
Alternator weight/kg: 32.600
Rotor weight/kg: 13.235
Rotor-moment of inertia (I)/kgm²: 2.424
Prime mover Wärtsilä diesel engine type 20V34SG

Direction of rotation (seen to DE) CCW
Overspeed capability 1,25 x rated speed f. 2 min.
Dynamic balancing: Balancing will be done with half key on shaft end.
date: 15.03.2006
W20V34SG
.
Mounting of coupling halve: A coupling hub, readily machined and balanced, delivered by
Wärtsilä free AvK factory will be mounted on the generator
shaft end after the factory test run.
Terminal box location (seen to DE) On top of NDE bearing shield, connections see circuit diagram
Cable outlet To right hand side (unless otherwise confirmed ) via undrilled
cable gland plates.
Gland plates made of non-magnetic material.
Outlet terminals/pcs. 4
Current transformers: Built-in in terminal box: 2 x 3 pcs. current transformer for
measuring and protection functions. Transformation ratio
600/5/5 A, class 5P10/5P10, 2 x 20 VA.
Voltage transformers: No VTs for external use provided.
Excitation transformers: All VTs and CTs required for proper excitation and regulation
(ABB Unitrol1000) are included in addition to the above
mentioned.
Auxiliary connections: Separate terminal box for low voltage connections
(temperature monitoring, heater, excitation terminals,
regulator), connections see circuit diagram K850.3.104.
Bearings Flanged (bracket mounted) sleeve bearings, self-contained,

with oil-ring lubrication, incl. circulation pump and oil coling
unit for DE bearing (to be connected to 400V 3~) are included
(if needed)
Bearing isolated at non-drive end.
Driven end equipped with earthing brush
Enclosure IP 23, acc. to IEC 34 Part 5 (machine)*

IP 54, acc. to IEC 34 Part 5 (terminal box)
Cooling type IC 01
Cooling air flow: Cooling air is drawn-in at both sides and axially at NDE
bearing shield, moved by 1 shaft-mounted radial fan, and
blown-out upwards at DE bearing shield via top-mounted
cover.
Remark: IP 23 is performed under operation. At standstill, the
enclosure is IP 21.
Air inlet filter: Attached at cooling air inlet openings.
Cooling air quantity: Approx. 8,6 m/s.sec.
Electronic voltage regulator:

Type: ABB Unitrol 1000-15 on mounting plate acc. to Wärtsilä
Standard.
Supplied by: AvK
Mounting: AVR to be mounted within the switchboard.
Testing and adjustment: Done at AvK test field together with the alternator.
Excitation transformer data: T25/T26: 11kV / 110V, 10VA, cl. 0,5,

Voltage transformers with integrated protection switch FS1
Droop transformer T6: 1000/1A, 5P5, 3VA
Special equipment, accessories, testing

Over temperature protection 2 x 3 x PT 100 in stator windings
1 x PT 100 per each bearing
Anti-condensation heater Built-in, connection to 400 V 1~ +/- 10%, 50 Hz,
rated power consumption 1000 W
Droop transf. f. parallel oper. Included
Factory testing Standard works test according Wärtsilä document 4V64L0037

are included and documented for each generator.
date: 15.03.2006
W20V34SG
.
Testing in presence of Wärtsilä: Wärtsilä and/or their customer are welcome to witness the
factory test.
Standard tests are: • Visual inspection (see below “Final check”)

• Measurement of cold resistances
• Residual voltage measuring
• Voltage balance
• Rotating field control / phase sequence check
• Inspection of bearings
• Vibration measurement at no load
• Load characteristic at p.f. = 0,1
• Evaluation of efficiency (single losses method, only for the
1st alternator of each series).
• No load saturation curve (only for the 1 alternator of each
st
series).
• Short circuit curve (only for the 1st alternator of each
series).
• Adjustment of voltage regulator
• Voltage setting range
• Underspeed protection adjustment
• Parallel operation adjustment
• Sustained SCC
• Overspeed test at 120 % rated speed
• High voltage test
• Measurement of insulation resistance
Final check: General check and test of assembled parts, wiring, labels,
connection diagram, rating, heater, temperature elements etc.
Further tests: More tests like temperature rise measurement, noise testing
etc. can be performed on request.
Painting / surface conservation Standard surface preparation and primer

primer thickness 40 ... 60 µm,
final colour RAL 5019 (or actual agreement at order)
final paint thickness approx. 60 µm
Documentation: Included is the standard order documentation 5-fold in

German or English language, consisting of:
• General alternator description
• Description of regulation system
• General outline- and shaft drawings
• Connection diagram with legend
• List of spare parts
• Maintenance instructions
• Factory test reports and, if ordered, certificates of
classification societies.
Extended documentation and/or other languages are possible
at price addition.
Quality assurance Offer, order handling, manufacturing and testing are done
according to ISO 9001. Approval of DNV for ISO 9001 is
available.
Seite 1 Legende zum Schaltbild Nr. Legend to Circuit Diagram No.
Page 1 K 850.3.104 K 850.3.104
B5 Spannungsregler UNITROL 1000 Automatic voltage regulator UNITROL 1000

ACHTUNG: ATTENTION:
ABB Reglerbeschreibung 3BHS116747_E20 See ABB’s wiring diagram 3BHS116747_E20
Rev.: F Rev.:F for detailed AVR connections and
zum Anschluß und zur Einstellung des Reglers adjustments!
beachten!
F1 Schutzschalter für G3 Protection switch for G3
NUR IM STILLSTAND EINSCHALTEN ONLY SWITCH ON AT STANDSTILL
FS1 Schutzschalter für Spannungswandler T25,T26 Protection switch for voltage transformers
T25,T26
NUR IM STILLSTAND EINSCHALTEN SWITCH ON ONLY AT STANDSTILL
33-34,41-42 Meldung 33-34,41-42 Signal contacts
G1 Hauptmaschine Main machine
G2 Erregermaschine Exciter machine
G3 Hilfserregerwicklungen Auxiliary exciter windings
R11 Rotierender Varistor Rotating varistor
T6 Statikwandler für UNITROL 1000 Droop transformer for UNITROL 1000
..../1A 3VA 5P5 …./1A 3VA 5P5
T14,15,16 Stromwandler Current transformer detail
……./…./….A …../…..VA …..Fs…/ …P…. ……./…./….A …../…..VA …..Fs…/ …P….
T25,26 Spannungswandler Voltage transformer detail
......kV/ .....V 10VA Klasse 0,5 ......kV/ .....V 10VA Klasse 0,5
T32 Spannungswandler für G3 mit integriertem Voltage transformer for G3 with integrated
Schutzschalter F1 protection switch F1
F1 - NUR IM STILLSTAND EINSCHALTEN F1 - SWITCH ON ONLY AT STANDSTILL
V1 Rotierende Gleichrichter Rotating rectifiers
X1 Hauptklemmen Main terminals
X2 Klemmleiste für Regleranschluß Terminal strip for AVR connections
X4 Klemmleiste für Heizung, PT100 Terminal strip for heater, PT100
X5 Klemmleiste für Stromwandler Terminal strip for current transformers
ZUBEHÖR ACCESSORIES
Widerstandsthermometer PT100 Resistance Thermometer PT100
Statorwicklung Stator winding
A1 Phase U Phase U
A2 Phase V Phase V
A3 Phase W Phase W
A4 Phase U Phase U
A5 Phase V Phase V
A6 Phase W Phase W
A13 Lager, B-Seite Bearing, NDE
A15 Lager, A-Seite Bearing, DE
H Stillstandsheizung 230V 1500 W Anti condensation heater 230V 1500 W
Schnellentregung: Quick de-excitation:

Brücken UH1-24 und WH1-14 öffnen Open bridges UH1-24 and WH1-14
Entregungsschalter: 220 V AC De-excitation switch: 220 V AC

(nicht AvK Lieferumfang) 10 A (not AvK supply) 10 A
Erstellt am: 8.3.06 Issued on: 8.3.06
AvK geprüft von: Diegeler Checked by: Diegeler
Revision Nr.: 1 Revision No.: 1
Alternator type: DIG 167 … -8
No load and short circuit characteristic
U/UN - I/IN
1,40
1,30
1,20
1,10
1,00
0,90
0,80
0,70
0,60
0,50
0,40
0,30
0,20
0,10
0,00
0,00 30,00 60,00 90,00 120,00 If [A] 150,00
characteristics valid for type output

Alternator type: DIG 167
Overload Characteristic
5,0
Strom I 1/IN [p.u.]
4,5
Current
4,0
3,5
3,0
2,5
2,0
1,5
1,0
0,5
0,0
1 10 100 1000 Zeit [s] 10000
Time
Alternator type: DIG 167
P/Q-Diagramm / P/Q-characteristic
1,2
Wirkleistung (p.u.)
Active load (p.u)
1,1
0,9
0,8
0,7
0,6
0,5
0,4
0,3
0,2
0,1
0
-0,8
-0,7
-0,6
-0,5
-0,4
-0,3
-0,2
-0,1
0,0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1,0
1,1
1,2
untererregt Blindleistung (p.u.) übererregt
underexcited Reactive load (p.u.) overexcited
Wirkleistung Cos phi 0,95 Cos phi 0,9 cos phi 0,8
cos phi 0,6 cos phi 0,4 cos phi 0,2
PT100 Temperatur Fühler RTD’s PT100 Temperature Detectors
Einstellwerte für Meßinstrumente in der Schaltan- Adjustment Values for Measuring Equipment in
lage the Switchboard
Statorwicklungen: Stator windings:
Isolationsklasse Warnung°C Abschaltung°C Insulation Class Warning°C Shut down°C
Erwärmung nach B 125 130 Insulation class B 125 130

Erwärmung nach F 140 145 Insulation class F 140 145
Erwärmung nach H 155 160 Insulation class H 155 160
Lager: Bearings:
Lagertype Warnung°C Abschaltung°C Bearing Type Warning°C Shut down°C

Wälzlager / Gleitla- Roller / Sleeve
85 90 85 90
ger bearing
AvK empfiehlt jedoch generell, bei der Inbetrieb- Generally AvK recommends adjusting the shut
nahme die Abschaltwerte entsprechend den tat- down values by the commissioning according to
sächlichen Gegebenheiten einzustellen. Nach the actual conditions at site. After a test run with
einem Probelauf mit Nennlast über ca. 3-4 Stun- rated load of approx. 3-4 hours the temperature
den sollten die Temperaturfühler mit einem Ab- sensors should be adjusted with a distance of
stand von ca. 5 K zu den gemessenen Werten approx. 5 K to the measured values. By this ad-
eingestellt werden. Zu beachten ist bei dieser justment, the maximum possible cooling air inlet
Vorgangsweise, daß die max. mögliche Kühlluft- temperature should be considered.
eintrittstemperatur berücksichtigt wird.
This is first of all important for the temperature
Dies gilt besonders für die Temperaturüberwa- supervision of roller / sleeve bearings, as a tem-
chung der Wälzlager/Gleitlager, da ein Tempera- perature rise, generally, indicates a bearing dam-
turanstieg normalerweise auf Lagerschäden hin- age. However, this can only be registered when
deutet. Dies kann jedoch nur erfaßt werden, falls the warning and shut down level have been ad-
Warnung- und Abschaltlevel relativ nah auf die justed relatively close to the rated temperatures.
Nenntemperatur eingestellt sind!
Bunsenstraße 17 Dreieich branch
85053 INGOLSTADT, GERMANY Benzstraße 47-49
Phone: +49(0)841-792-0 63303 Dreieich, Germany
Fax: +49(0)841-792-250 Phone: +49(0)6103-5039-0
e-mail: infoavkin@newage-avkseg.com Fax: +49(0)6103-5039-40
Data Sheet PT100 Winding Temperature
Dimension and technical data:
check point
Hersteller EPHY-MESS
manufactor
Bezeichnung M-OK / KS PT 100
denomination
Einsatztemperatur -20 °C … +200 °C
operative temperature
Nennwiderstand 100 Ω at 0 °C
rated resistance
Schaltungsart 2 wire
wiring
Meßstrom recommended 1 - 2 mA
measuring current max 10 mA
Toleranzklasse B acc. to DIN EN 60751
tolerance class
Hochspannungsfestigkeit 3.0 kV / 50 Hz, 1 min.
dielectric test
Zuleitung type: cable, silver plated, PTFE
connection insulated
section: AWG 24/7
length: 500 mm
Fax: +49(0)6103-5039-40
Data Sheet PT100 Bearing Temperature
Dimension and technical data:
Hersteller Dittmer / Heraeus

manufactor
Bezeichnung screw-in resistance thermometer
denomination PT100
Einsatztemperatur -40 °C … +250 °C
operative temperature
Nennwiderstand Class B 100 Ω at 0 °C
rated resistance
Schaltungsart 2 wire
wiring
Meßstrom Max. 3 mA (0.5 … 3 mA)
measuring current
Toleranzklasse B acc. to DIN EN 60751
tolerance class
Hochspannungsfestigkeit n.a.
dielectric test
Zuleitung Copper wire 2x 1.5 mm²
connection
Fax: +49(0)6103-5039-40
____________________________________________________________________________________________________________________________________________________
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+39-02-98213-1 2020 Skedsmokorset
Finland Fax: +39-02-98281595 Postboks 220
klita@it.klueber.com 2021 Skedsmokorset
Klüber Lubrication Skandinavien A/S
Hämeentie 3 +47-64837800
00530 Helsinki
Japan Fax: +47-64837801
NOK Klüber Co., Ltd. klueber.no@sk.klueber.com
+358-9-8545610
1-12-15, Shibadaimon, Minato-ku
Fax: +358-9-85456130
klueber.fi@sk.klueber.com Tokyo 105-8585 Pakistan
+81-3-3434-1734 Industrial Contracting Trading Company
France Fax: +81-3-5472-6073 107, Anum Estate, Block 7/8
Klüber Lubrication France S.A.S. info01@nokklueber.co.jp Darul-Aman, C.H. Society
Z.I. des Auréats, 10 à 16 Allée Ducretet Kitaibaraki Plant Opposite Duty Free Shop
26014 Valence Cedex 955-4, Aza - Ohishi, Isohara, Isoharamachi Main Shahrah-e-Faisal
+33-4-75448426 Kitaibaraki-City, Ibaraki - 319-1541 P.O. Box No. 549
Fax: +33-4-75449336 +81-293-427320 / 425365 Karachi 74200
klueber@fr.klueber.com Fax: +81-293-426784 +92-21-4534490-92
info01@nokklueber.co.jp Fax: +92-21-4530428
Greece ictc@super.net.pk
E. Scazikis - L. Marangos S.A. Korea, Republic of Peru
P.O. Box 154 Klüber Lubrication Korea Ltd. Dicomet S.R.L.
57022 Sindos Seoul Head Office: Av. Eduardo de Habich 111
Industrial Area of Thessaloniki Rm. 901, Samhwan Camus Bldg. 17-3 Urb. Ingenieria
+30-2310-797640 Yoido-Dong, Youngdungpo-ku Lima 31
Fax: +30-2310-795246 Seoul, 150-874 +51-1-4812555
info@scazikis-marangos.gr +82-2-7825151 Fax: +51-1-3825858
techn.skg@scazikis-marangos.gr Fax: +82-2-7849900 dicomet@hotmail.com
Athens Office: klueber@klueber.co.kr
E. Scazikis - L. Marangos S.A. Factory: Philippines, Republic of the
Serron Street 2 562 Okmyung-ri Daesong-myun, Nam-ku Diversified Holdings, Inc.
10441 Athens Pohang, Gyungbuk 790-840 Rm. 300 DHI Bldg., # 2 Lapu-Lapu Ave.
+30-210-5296900 +82-54-278-5151 Victoria St., Magallanes Village
Fax: +30-210-5223412 Fax: +82-54-278-5155 Makati City 1232
techn.ath@scazikis-marangos.gr klueber@klueber.co.kr Metro Manila
+63-2-8518385 /8528568
Guatemala Lebanon Fax: +63-2-8522786
Nativo Trading, Ltda. Cyprus klubphil@iconn.com.ph
km 16,5 Carretera a San José Pinula
Empresarial San José, Interior no. 8 Malaysia
Apartado Postal: 2212 Klüber Lubrication (Malaysia) Sdn Bhd
Guatemala, C.A. No. 17 Jalan PJU 3/49
+502-6637-5289 / -5293 Sunway Damansara Technology Park
Fax: +502-6637-5288 47810 Petaling Jaya
nativo@guate.net.gt Selangor Darul Ehsan
+60-3-78034954
Hungary Fax: +60-3-78034947
PRACTILUB Kft. sales@my.klueber.com
Késmárk u. 9 North Malaysia Office:
1158 Budapest
No. 22A (1st Floor) Persiaran Mahsuri 1/2
+36-1-2310079
Sunway Tunas
Fax: +36-1-3796473 11900 Penang
practilub@practilub.hu
+60-4-6469335
Fax: +60-4-6451669
sales.north@my.klueber.com
____________________________________________________________________________________________________________________________________________________

Poland Slovenia United States of America
KLÜBER LUBRICATION POLSKA sp.z o.o. PETROL d.d. Headquarters:
ul. Wierzbiecice 44 a Dunajska 50 Klüber Lubrication North America L.P.
61-558 Poznań 1527 Ljubljana 32 Industrial Drive
+48-61-8700790 +386-1-4714176 Londonderry, N.H. 03053
Fax: +48-61-8793805 Fax: +386-1-4714104 +1-603-647-4104
office@pl.klueber.com ales.arnsek@petrol.si Fax: +1-603-647-4105
Midwestern Group Office
Portugal South Africa, Republic of 512 West Burlington Avenue, Suite 208
Paulo C. Barbosa Lda. LaGrange, IL 60525
Rua do Negral, 1141 H/I Klüber Lubrication (Pty) Ltd.
P.O. Box 11461 +1-708-482-9730
4440-115 Campo Valongo/Porto Fax: +1-708-482-9407
+351-707-219544 Randhart / Alberton 1457
Fax: +351-707-219545 +27-11-908-2457 / 908-2458 / 908-2459 Southeastern Group Office
bemvindoas@solucoesdelubrificacao.pt Fax: +27-11-8647373 233 North Main Street, Suite 300 A
sales@za.klueber.com Greenville, SC 29601
Romania +1-800-889-4283
Super Plus S.R.L. Spain Fax: +1-864-467-0740
BD. Corneliu Coposu Nr 10/55 Klüber Lubrication GmbH Ibérica S. en C.
Western Group Office
Sibiu 550245 Carretera C-17, Km 15,5
572 East Green St., Suite 208
+40-269-2163000 08150 Parets del Valles (Barcelona)
Pasadena, CA 91101-2045
Fax: +40-269-216134 +34-93-5730711 / 5730666 / 5730667
+1-626-795-5455
bogdan.chelaru@superplus.ro Fax: +34 93-5730754
Fax: +1-626-795-6064
customer.service@es.klueber.com
KL Texas, L.P.
Russia Sweden dba SUMMIT INDUSTRIAL PRODUCTS
Klueber Lubrication OOO
Klüber Lubrication Skandinavien A/S 9010 County Road 2120
Skladochnaja ul., dom 2 A, strojenije 1
Box 601 Tyler, Texas 75713
127015 Moskau
194 26 Upplands Väsby +1-903- 5348021
+7-495-1011707/1011708
+46-8-59098600 Fax: +1-903- 5814376
Fax: +7-495-1011886
Fax: +46-8-59098601 info@klsummit.com
sales@ru.klueber.com
klueber.se@sk.klueber.com
Sankt Petersburg Office: Uruguay
Litejny prospekt, d. 22, of. 55 Switzerland Marx Representaciones Ltda.
191028 Sankt Petersburg Rambla O’Higgins 4937 - Oficina 603
Klüber Lubrication AG (SCHWEIZ)
+7-812-2724757 C.P. 11400 - Montevideo
Thurgauerstraße 39
Fax: +7-812-2750782 Postal address:
8050 Zürich
andrei.fiscovich@ru.klueber.com P.O. Box 18948 - Distrito 9
+41-44-3086969
Fax: +41-44-3086944 C.P. 11500 - Montevideo
Rostov-na-Donu Office:
info@ch.klueber.com +598-2-6137550
prospekt Semashko, d. 114, of. 310
Fax: +598-2-6137654
344010 Rostov-na-Donu
Thailand marx@esm.com.uy
+7-863-2500007
Fax: +7-863-2500008 TEXMAC Co. Ltd., Klüber Division
alexander.kupriyanov@ru.klueber.com Texmac Building
Venezuela
912 Srinakarin Road, Suanluang, Suanluang, RIESE INDUSTRIAL, C.A.
Samara Office: Bangkok 10250 Av. Abraham Lincoln Con Calle Olimpo
ul. Uritskogo, d. 19, of. 2, etash 9 Postal address: Torre Domus, Piso 3, Ofic. 3-C
443030 Samara G.P.O. Box 1594, Bangkok 10501 Sabana Grande, El Recreo
+7-846-2734362 +66-2-3625216 Caracas
andrei.gorev@ru.klueber.com Fax: +66-2-3625229 +58-212-7941362 / 7925949 / 7939720
kltexmac@cscoms.com Fax: +58-212-7938707
Kazan Office: riesei_import@cantv.net
ul. Kremljovskaja, d. 13, of. 202/B Turkey
420111 Kazan Klüber Lubrication Vietnam
+7-843-2920749 YAGLAMA ÜRÜNLERI SAN. VE TIC. A.S. VU MINH CO., LTD.
ruslan.safin@ru.klueber.com Cerkezköy Organize Sanayi Bölgesi 281 Doi Can Street, Ba Dinh District
Atatürk Cad. 10 Sok. No: 7 Ha Noi
Saudi Arabia, Kingdom of Cerkezköy/Tekirdag +84-4-7628495
REDA TRADING & DEVELOPMENT CO. FOR Postal address: Fax: +84-4-7628496
MACHINERY & EQUIPMENT LTD. PK 56, 59500 Cerkezköy/Tekirdag vuminhvietnam@vnn.vn
Khobar-Dammam Expressway +90-282-7581530 / 7581710
31952 Al Khobar Fax: +90-282-7582935 / 7582936 / 7581714 Yemen
+966-3-8572819 kltr@tr.klueber.com REDA INDUSTRIAL MATERIALS FZE
Fax: +966-3-8587503 Jebel Ali (Free Zone)
Ukraine Dubai/UAE
Singapore, Republic of Evrosmazki +971-4-8815027
Klüber Lubrication South East Asia Pte Ltd Borispolskaja str., 12-B Fax: +971-4-8815036
25 International Business Park 02099 Kiev
# 04-54 German Centre +380-44-5672646
Singapore 128384 Fax: +380-44-5672646
+65-6562-9460 office@evrosmazki.com.ua
Fax: +65-6562-9469
sales@klueber.com.sg United Arab Emirates
REDA INDUSTRIAL MATERIALS LLC
Singapore, Republic of P.O. Box 15004
Marine Teknik Pte. Ltd. Khalid Al Attar Tower, Suite 901
Blk 196, Pandan Loop # 05-17 Sheikh Zayed Road
Pantech Industrial Complex Dubai
Singapore 128384 +971-4-3325100
+65-6779-8366 Fax: +971-4-3325200
Fax: +65-6779-8266
marineteknikpl@pacific.net.sg United Kingdom
Klüber Lubrication Great Britain Ltd.
Slovakia Hough Mills, Northowram
KLH, s.r.o. Halifax, HX3 7BN
Sládkovičova 4 +44-1422-205115
96501 Žiar nad Hronom Fax: +44-1422-206073
+421-45-6722754 sales@uk.klueber.com
Fax: +421-45-6723475
klh@klh.sk
____________________________________________________________________________________________________________________________________________________

Wärtsilä Finland Oy
Doc. id: WDAAA158982 e
Date: 16-Apr-2003
Page: 1 (1)
Status: ISSUED
Made/Approved: KPA008 / KPA008
Name: REFERENCE INFORMATION
Subject: O&M Manuals - QR
SEE QUALITY RECORDS — VOLUME 8
CONSULTE LOS REGISTROS DE CALIDAD — VOLUMEN 8
CONSULTE OS REGISTOS DE QUALIDADE — VOLUME 8
VOIR LES ENREGISTREMENTS DE QUALITE — VOLUME 8
LÁSD MINŐSÉGI FELJEGYZÉSEK — 8. KÖTET
СМ. ОТЧЕТЫ О КОНТРОЛЕ КАЧЕСТВА – ТОМ 8
SIEHE QUALITÄTSPROTOKOLLE – VOLUM 8

Generator Instruction Manual

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Generator Instruction Manual

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Wartsila id : DBAA843102 - a

Wärtsilä Finland Oy 03/2007

1.1 Important notes for users The technical information

The operating instructions are to be kept Any unauthorized modifications and

2. Safety Precautions At particular dangerous points on the

Beside all safety notes in the operating Transportsicherungen.

Maschine nicht betriebsfähig!

Danger! This sign is mounted when the installation

All safety devices like covers, barriers and

ABSTANDSMAß-PROTOKOLL For operating the electrical machine the

If damages that were not noticeable by the

3.4 Unloading the generator

The unloading has to be performed in

Please refer to the freight

3.5 Storage of the generator

After unloading, the

Wrapped parts and assessories must not

The machine and packages have to be

If it is planned to store the

AvK Deutschland GmbH & Co. KG

Order No.: .............................................................

Generator Type: .............................................................

Operation Hours: .............................................................

Bearing design: Roller bearing o

Pos. 1.1 - 1.19

II. Mechanical Inspection

Pos. 2.1 - 2.20

III. Test Run

Pos. 3.1 - 3.14

IV. Maintenance Result

AvK Deutschland GmbH & Co. KG / Service Date: 22.07.2002

a) Location: building o marine o

b) Atmosperic conditions: dry o high humidity o

c) Ventilation: unrestricted o adequate o

a) Site duty: single o parallel o idle o

b) Duty cycle: 24 hours o daily o occasionally o standby o

c) Load condition: inductive o non linear o

d) Operation: manned o unmanned o

a) Dirt content: slight dust o light layer dirt o

b) Corrosion: none, very little o steel/iron o

c) Engine: Type: ....................

AvK Deutschland GmbH & Co. KG / Service Date: 22.07.2002

o 1.1 Examination of cable entry and cable shoes o

o 1.2 Examination of strain relief of connecting power cables o

o 1.3 Check of fixation of transformers installed o

o 1.4 Examination of cable entry and cable shoes o

o 1.5 Check of strain relief of connection cables o

o 1.6 Insulation test of stator windings o

o a) Stator winding phase U against ground o

o b) Stator winding phase V against ground o

o c) Stator winding phase W against ground o

1.7 Insulation test of stator windings

o a) Stator winding phase U against phase V o

o b) Stator winding phase U against phase W o

o c) Stator winding phase W against phase V o

o 1.8 Resistance measurement of stator o

AvK Deutschland GmbH & Co. KG / Service Date: 22.07.2002

o 1.9 Check and re-tightening of all screws and nuts o

o 1.10 Cleaning and examination of insulators for cracks o

o 1.11 Re-tightening of contact screws and nuts on o

o 1.12 Resistance measurement of auxiliary windings o

o 1.13 Insulation test of auxiliary windings o

o 1.14 Examination of anti-condensation heater o

Date: ________