User's Manual: MAN Material Numbers: 11.70123-2073 and 11.70123-0927

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User’s Manual Synchronous Machine

AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13

ABB ref. 1637HH101-111
November 2019 Project: MAN 5304532 Phnom Penh
MW, Cambodia Project
MAN Material Numbers: 11.70123-2073

and
11.70123-0927
Publish date:
2019-11-25 09:53 ABB
Synchronous Machine
AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13
ABB ref. 1637HH101-111
Project: MAN 5304532 Phnom Penh MW, Cambodia Project
Synchronous Machine
AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13
ABB ref. 1637HH101-111
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Synchronous Machine
AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13
ABB ref. 1637HH101-111
Synchronous Machine
AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13
ABB ref. 1637HH101-111
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AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13

ABB ref. 1637HH101-111
Contents
Introduction .............................1
Certificates ..............................2
Technical Specification ...........3
Mechanical Drawings ..............4
Electrical Drawings..................5
Manual ....................................6
Accessory Information.............7
Test Reports............................8
Check Lists..............................9
Additional Information ...........10
ABB
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AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13

ABB ref. 1637HH101-111
1.
Introduction
ABB
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Synchronous Machine AMG 1600UU12 DSER

Section 1- Introduction
Introduction
1. General information
This is the User’s Manual for the AMG1 600UU12 DSER Synchronous Machine manufactured
for project MAN 5304532 Phnom Penh MW, Cambodia Project and forms the main
documentation for this machine.
The purpose of this manual is to provide information for all aspects of installation, operation
and maintenance of the machinery and shows how to disassemble/assemble major components,
if required.
Actions shown in this manual are only to be performed by trained personnel authorized by the
user.
2. Site conditions
The machinery is to be used on a site with conditions according to Technical Specifications and
Conditions laid down by ABB Oy in their contract with the user, and nowhere else.
3. Important Note
The information in this document is subject to change without notice and should not be
construed as a commitment by ABB Oy. ABB Oy assumes no responsibility for any errors that
may appear in this document.
In no event shall ABB Oy be liable for direct, indirect, special, incidental or consequential
damages of any nature or kind arising from the use of this document, nor shall ABB Oy be
liable for incidental or consequential damages arising from use of any software or hardware
described in this document.
This document and parts thereof must not be reproduced or copied without the express written
permission of ABB Oy, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose.
4. General Safety
Carrying out certain operations, maintenance procedures and some handling procedures can be
dangerous or harmful if the correct safety precautions are not observed.
While it is important that these recommended safety procedures are observed, care near
machinery is always necessary: no list can be exhaustive, always be on your guard!
It is important that personnel are aware of the hazards that exist within their working
environment. Not only should they be able to identify these hazards, but they should be able to
deal quickly and efficiently with the situation by carrying out recognized safety procedures.
They should also be able to recognize warning signs (decals) and visual or audio signals.
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The following recommendations are for general guidance:

a. Always wear correctly fitted protective clothing, headwear and footwear. Loose or
baggy clothing can be lethal when working on or near rotating machinery. Clothing
should be laundered regularly. Clothing which becomes impregnated with oil or other
substances can constitute a health hazard due to prolonged contact with the skin, even
through underclothing.
b. As far as is practicable, work on or close to machinery only when they are stopped. If
this is not possible, keep tools, test equipment and all parts of your body well away
from the moving parts of the machinery.
c. Parts of the synchronous machine and its auxiliary equipment can reach high
temperatures. Protective clothing, particularly gloves must be worn at all times.
d. Many liquids used in machinery are harmful if swallowed or splashed into the eyes.
In the event of accidentally swallowing a potentially dangerous fluid, do NOT
encourage vomiting and OBTAIN MEDICAL ASSISTANCE IMMEDIATELY. Wear
protective goggles when handling liquids which are harmful to the eyes. If any liquid
is splashed into the eyes, wash out immediately and OBTAIN MEDICAL
ASSISTANCE IMMEDIATELY.
Safety is dependent on the awareness, concern and prudence of all those who operate and
service machines. The machinery may cause severe injury if incorrectly used. Personnel must
be aware of the potential hazards that exist when operating or maintaining synchronous
machines.
Before attempting to set up, operate or adjust synchronous machines, operators and
maintenance people must be technically qualified and must have received the appropriate
training.
Personnel must be familiar with the recommended procedures detailed in the Installation,
Operation and Maintenance chapters of the Section 6, Manual.
4.1 Symbols and decals

Personnel must be familiar with all the warning symbols and decals fitted to the machinery.
Failure to recognize a warning and read the associated safety instructions may result in injury or
death.
4.2 Electrical hazard

The synchronous machine and auxiliary equipment must be disconnected from the electrical
power supply during installation, maintenance or setting-up. All high-voltage parts must also be
earthed.
4.3 Moving parts

Covers must only be removed by qualified personnel when instructed as part of an installation,
maintenance or setting-up procedure. They must be re-fitted as soon as possible. Keep hands
and loose clothing clear of all moving parts.
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4.4 High temperatures

Parts of the machinery and its auxiliary equipment will reach high temperatures. Avoid contact
with them. Always wear protective gloves when working in the vicinity.
4.5 Electro-Static Devices (ESD)

Precautions must be taken to prevent damage to the electronic control devices of the
synchronous machine. Ensure that the operating environment is protected against ESD. Do not
touch electronic circuits while unpacking.
4.6 Magnetic fields

There is a magnetic field presence in the immediate area surrounding rotating machinery.
Ensure that devices that can be influenced or wiped (e.g. magnetic disks, credit cards, watches
etc.) by the effects of electro-magnetism are removed from the area.
4.7 Noise
Machine rooms can be extremely noisy and damaging to the ears. Ear protection should always
be worn where practicable.
5. Safety Instructions (High-voltage AC Machines)
5.1 General
High-voltage machines rated at more than 1 kV have dangerous live and rotating parts and may
have hot surfaces. All operations serving transport, connection, putting into service and
maintenance shall be carried out by responsible skilled persons (in conformity with
prEN 50 110-1 / DIN/VDE 0105 / IEC 364). Improper handling may cause serious personal
injury and damage to property.
5.2 Intended use

These high-voltage machines are intended for industrial installations. They comply with the
harmonized standards of the series EN 60034 / DIN VDE 0530. Their use in hazardous areas is
prohibited unless they are expressly designed for such use (follow supplementary instructions).
On no account, use degrees of protection ≤ IP 23 outdoors. Air-cooled models are designed for
ambient temperatures of -20°C up to 50°C and altitudes of ≤ 1000 m above sea level. Ambient
temperature for air-/water-cooled models should be not less than +5°C (for sleeve-bearing
machines, see manufacturer's documentation). By all means, take note of deviating information
on rating plate. Field conditions must conform to all rating plate particulars.
High-voltage machines are components for installation in machinery within the meaning of the
Machinery Safety Directive (MSD) 89/392/EEC. Putting into service is prohibited until
conformity of the end product with this directive has been established (follow particular local
safety and installation rules as e.g. EN 60204).
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5.3 Transport, storage

Immediately report damage established after delivery to transport company. If appropriate,
prevent commissioning of the synchronous machine. Lifting points are dimensioned for the
weight of the high-voltage machine, do not apply additional loads. If necessary, use suitable,
adequately dimensioned means of transport (e.g. rope guides). Remove shipping brace (e.g.
Roller or sleeve bearing locks, vibration dampers) before commissioning. Reuse the brace for
further transports.
When storing high-voltage machines, make sure of dry, dust-free and low-vibration (Vrms ≤ 0.2
mm/s) location (danger of bearing damage at rest). Measure insulation resistance before
commissioning. Always use space heaters in order to prevent humidity and condensation inside
of the machine. Follow manufacturer's recommendations.
5.4 Installation
Make sure of even support, solid foot or flange mounting and exact alignment in case of direct
coupling. Avoid resonances with rotational frequency and double mains frequency as a result of
assembly. Turn rotor, listen for abnormal slip noises.
Check direction of rotation in uncoupled state.
Mount or remove couplings or other drive elements only with appropriate means and cover
them with touch guard. Avoid excessive radial and axial bearing loads (see manufacturer's
documentation). The balance of the machine is done with half key as standard. The coupling
must also be balanced accordingly.
In case of protruding, visible part of key, establish mechanical balance.
Make necessary ventilating pipe connections. Models with shaft ends pointing upward are to be
provided with cover by customer. The ventilation must not be obstructed and the exhaust air,
also of neighbouring sets, should not be taken in directly.
5.5 Electrical connection

All operations must be carried out only by skilled persons on the high-voltage machine at rest.
Before starting work, the following five safety rules must be strictly applied:
• De-energize!
• Provide safeguard against reclosing!
• Verify safe isolation from supply!
• Connect to earth and short!
• Cover or provide barriers against neighbouring live parts!
De-energize auxiliary circuits (e.g. anti-condensation heating).
Exceeding the limit values of zone A in EN 60034-1 / DIN VDE 0530-1 - voltage ± 5%,
frequency ± 2%, form and symmetry - leads to higher temperature rise. Note rating plate
particulars and connection diagram in terminal box.
The connection must be made thus, that permanently safe electrical continuity is maintained.
Use appropriate cable terminations. Establish and maintain safe equipotential bonding.
The clearances between uninsulated, live parts and between such parts and earth must be
according to IEC standard.
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No presence of foreign objects, dirt or moisture is allowed in the terminal box. Close unused
cable entrance holes and the box itself in a dust- and watertight manner. For trial run without
output elements, lock fitting key. For high-voltage machines with accessories, check
satisfactory functioning of these accessories before commissioning.
The proper installation (e.g segregation of signal and power lines, screened cables etc.) lies
within the installer's responsibility.
5.6 Operation
Acceptable vibration values have to be determined according to application and corresponding
ISO standard. In case of deviations from normal operation - e.g elevated temperature, noises,
vibrations - disconnect the synchronous machine, if in doubt. Establish cause and consult the
manufacturer, if necessary.
Do not defeat protective devices, not even in trial run. In case of heavy dirt deposits, clean
cooling system at regular intervals.
From time to time, open closed condensation drain holes, if any.
Regrease antifriction bearing with relubricating device while high-voltage machine is running.
Follow instructions on lubricating plate.
In case of sleeve-bearing machines, observe the time limit for oil change.
Refer to manufacturer's documentation for noise level and information about the use of
appropriate noise-reducing measures.
5.7 Maintenance and servicing

Always follow manufacturer's instructions in Section 6, Manual.
6. Disposal and recycling instructions

ABB Oy is committed to its environmental policy. We strive continuously to make our products
environmentally more sound by applying results obtained in recyclability and life cycle
analyses.
Products, manufacturing process as well as logistics have been designed taking into account the
environmental aspects. Our environmental management system, certified to ISO 14001, is the
tool for carrying out our environmental policy.
For more information, see Chapter 10, Disposal and recycling instructions in Section 6,
Manual.
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AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13

ABB ref. 1637HH101-111
2.
Certificates
ABB
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AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13

ABB ref. 1637HH101-111
Contents
Certificates
Declaration of Incorporation can be found on the

side of the delivered machine
ABB
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AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13

ABB ref. 1637HH101-111
3.
Technical
Specification
ABB
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AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13

ABB ref. 1637HH101-111
Contents
Technical Specification
Technical Specification
ABB
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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 2011 ABB
TECHNICAL SPECIFICATION
Project name: 5304532 Phnom Penh 200 MW, Cambodia

Our order reference: 1637HH101-111
Customer’s reference: 5304532
Customer: ABB Automation Products GmbH
Final customer: MAN Energy Solutions SE
Application: Diesel/Gas engine
Type designation: AMG 1600UU12 DSER
NOTES
- max ground acceleration 0,04g = Ok
- Axial play = 0 +/-2,5mm = Ok
- Arcturus Design needs interconnection to the engine oil
- Cooling air temperature at the bearing at DE-side max. 50°C
- 98% efficiency with no negative tolerance at pf 0,8 and 100% load
CONTENTS
SECTION
1 PERFORMANCE DATA (Calculated values) 3

2 CONFIGURATION AND SCOPE OF SUPPLY 6
3 ACCESSORIES 9
4 P/Q DIAGRAMS 11
5 NO LOAD AND SHORT-CIRCUIT CURVE 15
6 COMPLEX SYNCHRONIZING COEFFICIENT 16
7 DYNAMIC V-CURVES 17
8 CURRENT THROUGH STATOR CORE LAMINATION VERSUS TIME 18
9 MAX. ALLOWED UNBALANCED LOAD FOR STANDARD GENERATORS 19
10 RERATING FACTORS FOR AMBIENT TEMPERATURE OR ALTITUDE 20
11 LOADABILITY OF STANDARD GENERATORS 21
12 OVERCURRENT LIMIT FOR STANDARD GENERATORS 22
13 UNDERFREQUENCY WITHSTANDING CAPABILITY 23
No. of sh.
Prep. Berick-Xing Yuan/CN 25.6.2019 TECHNICAL SPECIFICATION
Appr. 23
Resp. dept. PT
Document identification Lang. Rev. ind. Sheet
ABB Oy / Motors and Generators 3AFP 16377101 en B 1

TEMPLATE: TECHNICALSPECIFICATION.DOTX; FILENAME: 1637HH101-102_B_TECHSPEC.DOCX; PRINTDATE: 07/25/2019 1:59:00 PM; SAVEDATE: 07/25/2019 1:59:00 PM
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Revision Change Date Updated by

A Original 2019.06.25 Berick
B Updated Our ref. 2019.07.25 Berick

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1 PERFORMANCE DATA (Calculated values)
TYPE
Type designation: AMG 1600UU12 DSER
RATINGS
Output: 23152 kVA Direction of rotation
Duty: S1 (Facing drive end): CCW
Voltage: 15000 V Weight: 61650 kg
Current: 891 A Inertia: 13810 kgm^2
Power factor: 0.80 Protection by enclosure: IP23
Frequency: 50 Hz Cooling method: IC0A1
Speed: 500 rpm Mounting arrangement: IM7201
Overspeed: 600 rpm
STANDARDS
Applicable standard: IEC 60034-1
Marine classification: None
Hazardous area classification: None
Temperature rise stator / rotor: B/B
Insulation class: F
ENVIRONMENTAL CONDITIONS (max. values)

Ambient temperature: 43 °C Altitude: 1000 masl
Coolant temperature: °C
ASSUMED DATA
Driving equipment: Not Specified
Approx. engine power: 18900 KW
EFFICIENCY in % AT 95 °C
Engine power: 110 % 100 % 75 % 50 % 25 %
Efficiency @ power factor 0.80 97.97 98.00 98.01 97.75 96.48
Efficiency @ power factor 1.00 98.56 98.55 98.45 98.10 96.73
REACTANCES in %
XD (U): 189.4 XD’ (S): 32.0 XQ’’ (S): 24.2 X0 (U): 13.5
XQ (U): 94.6 XD’’ (S): 21.8 X2 (S): 23.0 XP (S): 26.4
X1 (U): 15.8 (S) = Saturated value, (U) = Unsaturated value
TIME CONSTANTS (sec.) AT 75 °C

TD0’: 5.251 TD’: 0.977 TQ0’’: 0.1792 TA: 0.184
TD0’’: 0.02739 TD’’: 0.01890 TQ’’: 0.0503
RESISTANCES AT 20 °C
Stator winding: 0.0349 Ω Field winding: 0.2032 Ω
Excitation winding: 8.6 Ω

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SHORT CIRCUIT
Short circuit ratio: 0.60
Sustained short circuit current: 1.6 p.u. (rated excitation)
> 3.0 p.u. (during boosting)
Sudden short circuit current: 4100 A (symmetric RMS)
10400 A (peak value)
VOLTAGE VARIATION
Maximum allowed amount of starting load:
Maximum voltage drop Power factor Load
15 % 0.1 10100 kVA
15 % 0.4 11000 kVA
15 % 0.8 17000 kVA
20 % 0.1 14200 kVA
20 % 0.4 15400 kVA
Voltage drop at sudden increase of rated load: 20 %
Voltage rise at sudden drop of rated load: 27 %
REACTIVE LOADING
Steady state reactive loading at rated excitation: 19350 KVAR (lagging)
Steady state reactive loading at zero excitation: 9050 KVAR (leading)
TORQUE
Rated load torque (Calculated of rated output in kVA): 442200 Nm
The peak values of sudden short circuit air gap torques:
2-phase short circuit: 580 % 3-phase short circuit: 420 %
BEARINGS
D-end: Sleeve, flood lubricated, locating N.D-end: Sleeve, flood lubricated, free
D-end bearing oil flow: 15.0 liter / min N.D-end bearing oil flow: 8.0 liter / min
D-end oil viscosity: ISO VG 150 N.D-end oil viscosity: ISO VG 150
Maximum axial play: ±2.5mm DE Bearing heat dissipation：3.4 kW
NDE Bearing heat dissipation：3 kW
TERMINAL CONNECTIONS (Viewed facing drive end)

Direction of main connection: Left down
Direction of zero connection: Left down
EXCITATION
Exciter field Power to the exciter field:1.22kW

No load: 4.0 A 44.0 V Exciter pole pairs: 17
Rated load: 10.6 A 115.5 V TD0’（sec）AT °75: 0.25741
TD’ (sec) AT °75: 0.1130

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OTHER
Stored energy constant (rotational energy divided by rated effect): 0.83 s
Earth capacitance (1-phase): 0.21 µF

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2 CONFIGURATION AND SCOPE OF SUPPLY
GENERAL
The generator is designed to operate together with a diesel or a gas engine. Compliance with
the maximum vibration level of the genset to be verified by the genset manufacturer who is
responsible for the full compatibility of all components of the genset according to ISO 8528-
5:2005, §15.10. Sleeve bearings wear rapidly at speeds below nominal. ABB requires customer
to specify jack-up units if frequent starting cycles or slow-turning operation are expected.
CONSTRUCTION
The stator frame is a rigid welded steel structure construction. The stator core is built of thin
electric sheet steel laminations which are insulated on both sides with heat-resistant inorganic
resin. The radial cooling ducts in the stator core ensure uniform and effective cooling of the
stator.
The rotor consists of a shaft, a hub with cylindrical or rim fitted directly on the shaft and poles
fixed on the rim. The shaft is machined of steel forging. The poles are manufactured of 2 mm
sheet steel and bolted to the hub. The pole laminations are pressed together with steel bars
which are welded to the end plates.
All windings are completely vacuum pressure impregnated with high quality epoxy resin. The
windings are provided with very strong bracing which withstands all expected mechanical and
electrical shocks and vibrations as well as chemicals. For more information ask for brochure
"MICADUR-Compact Industry Insulation System".
The stator frame and pedestals are made of fabricated steel. The stator frame is closed with
steel panels that guide the ventilation air and provide the degree of protection required. The
pedestals are integrated to stator frame.
According to IM7201 the machine has two pedestal bearings. The feet are at the bottom of the
machine. Cylindrical shaft end.
FOUNDATION
The machine can be mounted using shimming, machined blocks, chock fast or on grouted sole
plates or bed plate. Before using other mountings, contact us.
COOLING
The machine has two shaft mounted fans inside. The surrounding air is used for cooling. The
cooling air is drawn in through air filters (self charging electrostatic panels) and blown out to the
surrounding environment.
CONTROL SYSTEMS
A three phase transformer supplies the excitation power to the field winding of the shaft driven
three phase exciter under the control of the digital automatic voltage regulator (AVR) type ABB
UNITROL UN1020. A three phase voltage feedback is supplied by the voltage transformer. A
current feedback is provided by the current transformer. The transformers are installed in the
generator.
Thanks to a permanent magnet pole in the exciter no external power source is required for initial
excitation at start-up. The permanent magnet pole is already magnetized by the generator
manufacturer. Should the re-magnetization of the permanent magnet be necessary, rated values

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for re-magnetization given on the main connection diagram of the generator are used. Thanks
to Soft Start function it is possible to avoid over shooting at start-up.
Excitation power at short circuit is supplied by the CTs through rectifier. At nominal voltage the
contactor is shorting the output of CTs (and preventing over excitation from these CTs). At a line
short circuit AVR will notice the voltage drop and connect CTs to give full short circuit excitation.
ECL-10 current limiter limits sustained short circuit current approx. 250 - 300 % of rated current.
The circuit breaker protects the field circuit and the AVR against thermal overload and short
circuit. The over voltage relay will trip the circuit breaker in excess of pre-set limit of over voltage
and thus interrupt the supply of the excitation power to the AVR.
Auxiliary supply can be 9 to 300 Vac (3-phase), 16 to 300 Vac (1-phase) or 18 to 300 Vdc.
UNITROL 1020 AVR can be operated using digital and analogue I/O signals, from local panel
or with CMT1000 PC software. CMT1000 is a commissioning and maintenance tool running
under Microsoft Windows. With CMT1000 the tuning of the AVR can be done easily, also by
using preset parameter files. The operation of a synchronous machine can be monitored and
controlled by an on-line power chart, four channel oscilloscope and by several measurements
and status indications with trending and memory functions. Measured data and parameters can
be saved to a file for future use and analysis.
UNITROL 1020 single channel AVR plate (dimensions: 425x650mm) includes:
- UNITROL UN1020 AVR
- Excitation breaker (ac) and MCB for Upwr supply
- Over voltage relay (stator over voltage protection)
- Boost circuit with ECL-10 current limiter
- Standard software functions as per UNITROL UN1020 brochure, including
- AVR/FCR/PF/VAR
- Limiters
- Modbus TCP
- Rotating diode monitoring
- Voltage matching prior to synchronizing
- VDC mode
- Synchronization (option)
- Event logger (option)
- Data logger (option)
- Real time clock (option)
- PSS (option)
- Interface for I/O signals:
Inputs
- Excitation On command
- GCB close command
- Setpoint Increase
- Setpoint Decrease
- Parallel with grid
- PF or VAR
- Synch.
- PF remote SP
- Remote SP enable
- VDC enable
Outputs
- Speed increase (sync. mode)
- Speed decrease (synch. mode)
- Net 1 selected
- Net 2 selected
- FRT output
- Alarm
- Trip

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- Overvoltage status
- GCB status
- Excitation On/Off Status
- CMT 1000 Commissioning and
- PID setting calculation tool
TESTING
Testing is according to IEC and ABB internal requirements. The test may be observed by the
customer without extra charges. The test procedures is described as following:
Routine(for all, items 1-13) and efficiency tests(for first, items 14-16) of the generator:
Routine tests
*1. Visual inspection
*2. Air gap measurement and bearing clearance check
*3. Insulation resistance measurement
*4. Resistance measurement of windings and elements
5. Direction of rotation
6. First running: checking of bearings
7. No-load point, U1=U1N, N=nN
8. Short-circuit point, I1=I1N, n=nN
9. Tests with voltage regulator
- testing of voltage setting range
- setting of under frequency limit and function testing
- initial voltage build-up and voltage regulation speed at no-load
- measuring of sustained short-circuit current
- measuring of remanence voltage
10. Overspeed test, t = 2 min, n = 1.2 * nN
11. Vibration measurement at no-load, U1 = U1N, n = nN
12. High voltage test:
- stator winding
- rotor winding
- field winding
- space heaters
- Pt-100 (stator)
- Pt-100 (others)
13. Insulation resistance measurement
14. No-load curve, U1 = f(Ir), n = nN
15. Short-circuit curve, I1k = f(Ir), n = nN
16. Losses and efficiency
* Tests to be completed before witness tests
(Performing order of the tests may differ from the listed above.)
SURFACE TREATMENT
Colour: RAL7040 Grade: C3-H, Standard color

Surface treatment C3 according to the ISO 12944, for standard industrial environment with low
salinity. Surface treatment according to ISO 8501-3 P2.
DOCUMENTATION
User's Manual in electronic format. Documentation language is English.

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3 ACCESSORIES
No pc/pcs Item
6 PT100 for stator winding
2 Double PT100 for sleeve bearings (radial bearing surface) PYR 2PT100R-0/4
1 Varistor SXV 40K550 C
6 Diode LND SD600N20PC

ABB Stock code: 3AFP9875575
1 Automatic Voltage Regulator (AVR) system 3BHE044620R6107

Digital-ABB Unitrol 1020 1CH MAN system FULL+ PSS on a plate.
1 1PT - Voltage transformer for exc.power & actual value meas.

15000/165/110 V
Secondary 1: 165 V 3200VA for excitation
Secondary 2: 110 V 300VA, 10VA class 0.5 for actual value measurement
3 3CT - Current transformer for short circuit exc.power

1000/7.5 A, class PX
1 2CT - Current transformer for actual value measurement

1000/1A, 5 VA, CL 0.5, 50/60 Hz
3 4CT - Current transformer for differential protection

TPU54.11, 1000/1 A, 50/60 Hz
Core 1: 10VA, 5P20
1 Top mounted direct air cooling unit incl. air filters
20 Air Inlet Filters

Pliotron CR, Galvanized Steel, 500*625
3 Anticondensation heater
Voltage (1-ph.) 380-440 V, power 3 x 720-970 W
Voltage (3-ph) 660-760 V, total power 2160-2910 W
1 Auxiliary terminal box B3A , With Roxtec EzEntry cable transits.
1 Auxiliary terminal box B3B , With Roxtec EzEntry cable transits.
1 Drive-end sleeve bearing ZLH SCZCB36-340CCX1

Foot mounted bearing for land applications. flood lubrication, no oil ring.
1 Non-drive-end sleeve bearing ZLH SCZCQ36-340EPCY2

Foot mounted bearing for land applications. flood lubrication, no oil ring.
Insulation between bearing house and shell

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2 Jack-up Unit
Own unit for each bearing. For unit details see hydraulic circuit diagram.
Check OPTIONS availability in User Manual
Start engine, Switch-on JU: 5 s before start-up;
Start engine, Switch-off JU: if 75% nominal speed is reached.
Stop engine, Switch-on JU: if speed is less than 75% of nominal speed;
Stop engine, Switch-off JU: when machine is stopped
2 Control Valve and Pressure Meter for oil inlet-ZLS SVDN20 and UD1/0...400KPA
2 Oil outlets at both sides of the bearings.
1 Extended lubrication oil piping for bearings
1 3+N terminals in the main terminal space ,multidiameter cable entry system for phase
and neutral cables.
1 Main terminal space B1- IP55
1 Shaft earthing brush.
1 Fastening bolts,
1 Guiding pins
2 Sole plates, anchor bolts and shims
1 Mounting of machined coupling half

The machined coupling half must be delivered latest 2 weeks before the delivery date of
the generator to our factory.
1 Internal protective varnish

Rotor and stator moisture resistant varnish
1 Connection parts for ducting connection

Flange for possibility of air duct connection for air outlet
1 MAN Special Name Markers for KKS Number
1 Special Color for lifting eyes and fastening points
1 Standard halogen free cables

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4 P/Q DIAGRAMS
4.1 P/Q diagram at rated voltage
ABB Motors and Generators

Type: AMG 1600UU12 DSER
Sn: 23152 kVA cos: 0.80 Tn: 442171 Nm
Un: 15000 V n: 500 rpm In: 891.1 A
f: 50 Hz
P / Q -DIAGRAM
1. Stator current at rated load 5. Minimum excitation limit

2. Nominal working point 6. Stability limit
3. Active power limit 7. Steady state stability limit
4. Rated rotor current kW
45000
0.9 0.95 0.95 0.9
40000
0.8
0.8
35000
4 1.2
7
6 30000
1.0
25000
1
0.75
0.6 0.6
2 3 20000
0.5
15000
0.4 0.25 0.4
10000
0.1
5
5000
0
-30000 -20000 -10000 0 10000 20000 30000 kVAr

25/616
4.2 P/Q diagram at 95% voltage

Sn: 23152 kVA cos: 0.80 Tn: 442171 Nm
U: 14250 V n: 500 rpm In: 938 A
f: 50 Hz
P / Q -DIAGRAM

45000
0.9 0.95 0.95 0.9
40000
0.8
0.8
35000
4 1.2
7 30000
6
1.0
25000
1
0.75 0.6
0.6
2 3 20000
0.5
15000
0.4 0.4
0.25
10000
0.1
5
5000
0
-30000 -20000 -10000 0 10000 20000 30000 kVAr

26/616
4.3 P/Q diagram at 105% voltage

Sn: 23152 kVA cos: 0.80 Tn: 442171 Nm
U: 15750 V n: 500 rpm In: 848.7 A
f: 50 Hz
P / Q -DIAGRAM

45000
0.9 0.95 0.95 0.9
40000
0.8
0.8
4 1.2 35000
7
6
1.0 30000
0.75
25000
1
0.6 0.6
2 3 20000
0.5
15000
0.25
0.4 0.4
0.1
10000
5000
0
-30000 -20000 -10000 0 10000 20000 30000 kVAr

27/616
4.4 P/Q diagram set points

RATED VOLTAGE (15000V) 95% OF RATED VOLTAGE (14250V) 105% OF RATED VOLTAGE (15750V)
P
Set point [kW] Q [kVAr] Set point P [kW] Q [kVAr] Set point P [kW] Q [kVAr]
Point 1 0 -9070 Point 1 0 - 7970 Point 1 0 - 10220
Point 3 8210 - 15400 Point 3 7570 - 13810 Point 3 8890 - 17080
Point 6 18500 0 Point 6 18500 0 Point 6 18500 0

28/616
5 NO LOAD AND SHORT-CIRCUIT CURVE

Sn: 23152 kVA cos: 0.80 Tn: 442171 Nm
Un: 15000 V n: 500 rpm In: 891.1 A
f: 50 Hz Ir (1.0): 219.5 A Ir (1.2): 320.8 A
Ir/Iag (1.0): 1.143 Ir/Iag (1.2): 1.393
Excitation current (A)

E/Un I/In
1.4 2.8
2
1
1.2 2.4
3
1 2
0.8 1.6
0.6 1.2
0.4 0.8
1 Air-gap line, Iag
2 No load voltage
3 Short-circuit current
0.2 0.4
0 0
0 200 400 600 800 Ir (A)

29/616
6 COMPLEX SYNCHRONIZING COEFFICIENT
Complex synchronizing coefficient

AMG 1600UU12 DSER
k (1/rad)
4.00
1
3.60
3.20 2
2.80
2.40
2.00
1.60 4
3
1.20
00.80
00.40
00.00
0 1 2 3 4 5 6 7 8 9 10
Oscillation f requency (hz)
1 = Sy nch. f actor at rated load

2 = Sy nch. f actor at no load
3 = Damping f actor at rated load
4 = Damping f actor at no load
REFERENCE: Dieter Rumpel: Das Drehmomentv erhalten v on Drehstromgeneratoren

bei sinusf örmigen Pendelungen, MTZ, 26.Jahrgang Hef t 2 1965 s. 35-42
M/ M=k * d (9)
k = M / M / d * (cos(e)+j sin(e)) (10)
k = complex sy nchronizing coef f icient,
the real part is sy nchronizing (or elastic) f actor,
the imaginary part is damping f actor
d = the oscillating part of rotor angle in electrial radians
d = p * dm, where
p = the number of polepairs and
dm = the angle in mechanical radian
M = the base torque of generator 442150 Nm
e = the phase dif f erence angle between the oscillating
rotor angle and the corresponding torque

30/616
7 DYNAMIC V-CURVES
Ist-Ir Curves 25.06.2019
AMG 1600UU12 DSER U = UN
Ist/In
1.50
1 2 3 4 5 6 7 8 9 10 11
1.25
1.00
cap ind
0.75
0.50
0.25
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
Ir/Iri
1: pf 0.50 cap 4: pf 0.90 cap 7: pf 0.95 ind 10: pf 0.70 ind
2: pf 0.70 cap 5: pf 0.95 cap 8: pf 0.90 ind 11: pf 0.50 ind
3: pf 0.80 cap 6: pf 1.00 9: pf 0.80 ind

31/616
8 CURRENT THROUGH STATOR CORE LAMINATION VERSUS TIME
70
60
50
40 C
I/A
30
20
10
B
A
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
t/sec
A = NEGLIGIBLE ARC BURNING

B = SLIGHT BURNING
C = SEVERE DAMAGE

32/616
9 MAX. ALLOWED UNBALANCED LOAD FOR STANDARD GENERATORS
The standard three phase synchronous generators are capable to operate on an unbalanced system so
that the ratio I2/In does not exceed the curve in the figure below.
I2 / In %
500
400
300
200
100
0
0 10 20 30 40 50 60 70 80 90 100
sec
The curve basis on the formula (I2/In) 2 * t = 20 sec,

where I2 is the counter rotating component of stator current In and t time in seconds.
Max. continuous value for I2 is 10%

33/616
10 RERATING FACTORS FOR AMBIENT TEMPERATURE OR ALTITUDE

34/616
11 LOADABILITY OF STANDARD GENERATORS

S /Sn
1.6
1.5
1.4
1.3
1.2
1.1
0.9
0 10 20 30 40 50 60
min
110% FOR 1 HOUR 110% FÜR EINE STUNDE

100% CONTINUOUSLY 100% DAUERND
Sn = rated output / Nennscheinleistung

S = output with rated P.F. at six-hour intervals /
Leistung bei dem Nennleistungsfaktor in jeder sechsten Stunde

35/616
12 OVERCURRENT LIMIT FOR STANDARD GENERATORS
I / In
11
10
9
8
150 % for 2 minutes / 150 % 2 Minuten
7
125 % for 15 minutes / 125 % 15 Minuten
6 110 % for 1 hour / 110 % 1 Stunde
5
4
3
2
1
0 5 10 15 20
sec
In = rated current / Nennständerstrom

I = max. allowed current at six-hour intervals /
Max. zulässiger Strom in jeder sechsten Stunde

36/616
13 UNDERFREQUENCY WITHSTANDING CAPABILITY
UNDERFREQUENCY WITHSTANDING CAPABILITY AFTER CONTINUOUS OPERATION AT

RATED OUTPUT
FREQUENCY LOAD AT RATED VOLTAGE

% P.F.=0.8 P.F.=1.0 No load
P=Pn P=Pn P=0
104 cont. cont. cont.
95 30 min cont. cont.
92.5 2 min 30 min cont.
90 2 min cont.
87.5 30 min
85 2 min

37/616

AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13

ABB ref. 1637HH101-111
4.
Mechanical
Drawings
ABB
38/616

AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13

ABB ref. 1637HH101-111
Contents
Mechanical Drawings
Main Dimensions .................................3915055
Cross Sectional Drawing ......................9116829
Generator Foundation ..........................3915061
Rotor Drawing ......................................3915060
Removing Rotor ..................................9163935
Transport Locking ................................9098852
Transport and Hoist .............................9099600
Main Dimensions of Jack-up Unit ........9162927
Air Outlet Flange ..................................9100062
ET-Dimension ......................................5131408
D-end Bearing ......................................9162867
N-end Bearing ......................................9012478
Base Force Calculation
ABB
39/616
On the other side

(1HE) On the other side
3HE (2HE)
5304532 Phnom Penh 200 MW, Cambodia

40/616
41/616

C
F
E
Gen eral to lera nces f or l in ear a nd a ngul a r dime nsi o ns We r e s e r v e a l l ri g ht s i n t hi s d o c u me n t a n d i n t h e i n f o r ma t i o n
B
A
S y mb o l s f o r r ou g hn e s s a c c or di n g t o IS O 1 3 0 2 ,
c on t a i n e d t h er e in . R e pr o d u c tio n , us e o r dis cl o s u r e t o t hi r d par t i e s
a nd geometric al to ler ances: IS O 2768
wit ho u t e x p r es s a ut h o r i t y is s t r i c t l y fo r bi d d e n.
Ref e re nt ia l st a nd ards 9 AD A 422 , DIN 71 6 8T. 1, DI N 71 6 8T. 2 9 A DA 431 c AB B B U M o t o rs a n d G e n e r a to r s
AB B A 2 B F I
1
1
2
2
430
3
3
3810
4
4
42/616
5
5
350
500
02
6
6
Approved
Reviewed
Pre par ed
Distribution
Custo mer ref.
Addi tional information
AR
Functi onal code Order No.

Original dwg
with se parat e No.
BU Motors and Generators

Sepa rate part lis t
Responsi ble de par t me nt
7
7
Weight
Type
Title
Our ref.
Docu me nt No.
ROTOR DR AWING
AMG 1600UU12 DSER
3GYB3915060
8
8
Protec tion/ Cooling
B
Mounting Size
Revision She et
Poles
Scal e
12
A2
EN
1/1
Language
1: 10
43/616
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46/616
47/616
48/616
49/616
ABB code: 3AFP9162867 ver: A
A-A B-B
414 592
362
30
30
f 31 $
1
14,15
2
20
4-6
$
290-3
29 10,13
8 11,12 a
28 7
25 $
9
e H7 h b
340
340
d
$20 $
h rng VII
40
B o 3
60
e
bor
165
25
200 $ 94
c
15
210
V 28 30
250
220-0,1 49 II
d
310
350
55
380
207 # 5
g VIII
IV VI g 100
III
I
27
63
75
c 29
46
82
16,17 27 19
280 18
400
Durchfluss-
richtung
beachten!
Consider
I Schmierstoffablassschraube G 3/4* C-C direction
705 oil flow!
II Anschluss für Temperaturfühler rad. G 1/2
III Schmierstoffstandsauge G 2 1/2 645

Anschlussgewinde nach DIN ISO 228
IV Schmierstoffablauf DN65 (DIN 2576) G 2 1/2 threads acc. to DIN ISO 228 570
raccord fileté suivant DIN ISO 228
V Anschluss für Schmierstoffzulauf G 3/4
d d d t
VI Sauganschluss Hydrostatik G 3/8 1 2 3 1
Anflaechung
spot face
G 3/8 24 32 2
VII Hydrostatikanschluss G 1/4
G 1/2 29 37 2.5
lamage
3
1
d
VIII Anschluss für Überdruckventil G 3/8 G 3/4 34 50 2.5 02

25
G 3/4* 34 - 2.5
G 2 1/2 90 112 4
452
360
I oil drain plug BSP 3/4"* t

1
10
II connection for thermosensor BSP 1/2"
III oil level sight glass BSP 2 1/2"
IV oil outlet DN65 (DIN2576) BSP 2 1/2"
V connection for oil inlet BSP 3/4"

20-24, 26
VI suction line hydrostatic BSP 3/8"
Anzugsmoment 25
VII connection for hydrostatic BSP 1/4"
torque Nm
VIII connection for over pressure valve BSP 3/8"
a 610
b 75 BEARING SCZCB36-340
Alle Anschlüsse können wahlweise c 85 Diese/Alle Zeichnungen, Modelle, Schablonen, Daten und Programme etc. Ces/Tous ces dessins, modèles, gabarits, données et programmes etc.
These / All drawings, models, templates, data and programmes, etc.
bleiben unser ausschließliches Eigentum. Sie werden nur zu dem ver- shall remain our exclusive property. They are only handed over to
demeurent notre propriété exclusive. Ils ne sont confiés que pour
rechts oder links montiert werden d 60 einbarten Zweck anvertraut und dürfen zu keinem anderen Zweck verwendet
the agreed purpose and must not be used for any other purpose. le but convenu et ne peuvent pas être utilisés à d'autres fins.
werden. Kopien oder sonstige Vervielfältigungen einschließlich der Copies or other reproductions including storage, processing or Des copies ou d'autres reproductions, y compris la mémorisation,
Speicherung, Verarbeitung oder Verbreitung unter Verwendung distribution by using electronic systems may only be made to thele traitement ou la diffusion avec des systèmes électroniques,
e 75
agreed purpose. Neither originals nor copies may be handed over ne
elektronischer Systeme dürfen nur zu dem vereinbarten Zweck angefertigt to peuvent être réalisées que dans le but convenu.
third parties or be made available in any other form.
werden. Weder Originale noch Vervielfältigungen dürfen Dritten ausge- Il est interdit de remettre des originaux ou des reproductions
All connections can be mounted optionally händigt oder in sonstiger Weise zugänglich gemacht werden. à des tiers ou de les leur transmettre de toute autre manière.
on the right or on the left side f 20 Alle Rechte (für den Fall der Patent-, Gebrauchsmuster-, oder
Geschmacksmustereintragung) vorbehalten.
All rights (in case of registration of patent,
utility patent, design patent) reserved.
Tous droits réservés (pour le cas de l'immatriculation d'un brevet,
d'un modèle d'utilité ou d un modèle d'agrément).
Schutzvermerk nach ISO 16016 beachten Refer to protection notice ISO 16016 Se référer a la note des droits réservés selon l'ISO 16016
g 34 Allgemeintoleranz ISO 2768-mK-E Massstab 1:5 Werkstoff
h 10 P097553.ASSEM-02 Oberflaeche DIN ISO 1302 Format A1
Form- und Lage DIN ISO 1101
. . Datum Name Benennung

Gewicht: ca. 406kg . . Bearb.11.12.2017 Gru LAGER
. . Gepr. 11.12.17 Mi
weight: app. 406kg . .
SCZCB36-340
Paßmaß Abmaße . . Status: Freigabe
. . Zeichnungs-Nr.: Blatt
02 11.12.2017 Gru 1
340H7 +0.057 01 04.12.2017 Gru Werk P097552-02 1 Bl.
0.000 Version Bearb.Datum Bearb. Hannover
50/616
51/616
ABB Oy Date: 06/21/2019

Electrical Machines Calculated by: Berick
Our reference:
Machine type: AMG1600UU12 DSER
FORCES TO THE BASE Project: 5304532 Phnom Penh 200 MW, Cambodia
Initial data:
Machine type G M = motor, G = generator
Ouput P 23152 kVA
Speed N 500 r/min
Power factor Cos 0.8
Rated torque Tn 353.7 kNm
Stator weight Fst 30500 kg = 299.2 kN
Rotor weight Frt 30280 kg = 297.0 kN Bearings included
Machine width L 3650 mm
Gravity center of rotor GR 0.485 GR=(C…E)/(C…D)
Number of bearings Bn 2
Air gap DELTA 11 mm
Magnetic pull Fmagn 18.94 kN/mm => 10.4 kN
Shaft born static overtorque TMAXSS/TN 1
Number of stator systems 1
3-ph short circuit factor M3OIK 4.20
2-ph short circuit factor M2OIK 5.78
Stator factor Stfac 0.85 0,85 when bearing bracket integrated to frame, otherwise 1
Direction of rotation
Forces to the base kN
No load A +127
B +127
C +175
D +167
Rated load A +25

B +219
C +181
D +172
3-ph short circuit +534 2-ph short circuit +687

A A
-280 6 -433
-280 -433
B B
+534 +687
C +175 C +175
D +167 D +167
D
E
+
(rotor gravity center)
A B
D-END
File BASE FORCE CALCULATION.xlsx Page 1 (1) Print date 07/02/2019

52/616

AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13

ABB ref. 1637HH101-111
5.
Electrical
Drawings
ABB
53/616

AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13

ABB ref. 1637HH101-111
Contents
Electrical Drawings
Main Connection Diagram ...................3915242
Layout of Connection ...........................3916774
Terminal Box B3A for Accessories .......9166275
Terminal Box B3B for Accessories .....9166276
Exciter Rotor with Diode Bridge ..........5122424
AVR-plate, Dimensions ........................9155704
AVR-plate, Connection Diagram ..........9155705
ABB
54/616
HYD ROST ATI C J ACK-U P HYD ROS TA TIC J ACK- UP

OIL FIL T ER ELECTRICAL CLOGGING IN DIC ATOR S PRESSU RE SWIT CHES
D N
D N P 53S P 6 3S
3 3
1 1
2 2
1 2 1 2
51S1
51S2
61S1
61S2
53S1
53S2
53S3
63S1
63S2
63S3
X1a B3 B
PE
PE
D D N N

30 R2
30 R2
31 R2
31 R2
40 R2
40 R2
41 R2
41 R2
30 R1
30 R1
31 R1
31 R1
40 R1
40 R1
41 R1
41 R1
AMG 16 00 UU12 DS ER
3GYB3915242 B
55/616

56/616
57/616
58/616
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1 ver: B
ABB code: 3AFP9155704 2 3 4 5 6 7 8 9 10 11 12
A A
UL
©
LISTED
OPEN INDUSTRIAL CONTROL PANEL
No. X XXXXXXXX
-G10 -C01
B B
-V01
Product: 3BHEXXXXXX / -
Order Nr. XXXXXXXXX
-V02 Serial Nr. XXXXXXX

Date: DD.MM.YYYY / SV
FIDRI ref. PEL-4500031672 / 5780G105
C C
-V03
-F02
680
655
D D
-U01
-Q11 -K06 -K11
-V04 -K01 -K05 -K11.1
-R01
E E
-R11
-V05
-U02
-K03 -K07 -K12
UL Specific
Information
F F
8
-X1
O
-31
-33
-26
-32
-30
-34
-20
-21
-22
-23
-24
-27
-28
-29
-29
-29
-25
-29
-29
-29
-PE1
-PE3
-PE2
-10
-17
-11
-13
-15
-18
-16
-12
-14
-19
-9
-4
-5
-6
-1
-2
-7
-8
-3
G 400 2,5 G
425 155 -All dimensions in mm

-Weight: Approx. 15kg
General tolerances for linear and angular dimensions produced by machining

H assembled parts corresponding to ISO 2768 Roughness symbol corresponding to ISO 1302 Prepared: Based on: Sep. PL same no: anoth. no: Scale: Doc-type: Format: H
T. A. Sheeraz 03.12.2018 1:2 ZAB A1
Reviewed: Resp. dep:
Range of nominal
dimension mm
> 0,5
... 3.0
> 3
... 6
> 6
... 30
> 30
... 120
> 120
... 400
> 400
... 1000
> 1000
... 2000
> 2000
... 4000
> 4000
... 8000
> 8000
... 12000
> 12000
... 16000
> 16000
... 20000 Removal by machining optional obligatory prohibited S. Gentner 03.12.2018 IAPG-E Dimensional Drawing
Approved: Take over dep: Language:
Deviation
Range "coarse" ± 0,2 ± 0,3 ± 0,5 ± 0,8 ± 1,2 ± 2 ± 3 ± 4 ± 5 ± 6 ± 7 ± 8 Roughness grade N 11 N 10 N 9 N 8 N 7 N 6 N 5 N 4
S. Gentner 03.12.2018 UN1020 1CH MAN en
Deviation
Range "medium" x ± 0,1 ± 0,1 ± 0,2 ± 0,3 ± 0,5 ± 0,8 ± 1,2 ± 2 ± 3 ± 4 ± 5 ± 6 Roughness value Ra ( m) 25 12,5 6,3 3,2 1,6 0,8 0,4 0,2 Revision:
UN1020
No.of sh:
E 88427 1
We reserve all rights in this document and in the information contained General geometrical
3BHS581347_E01 therein. Reproduction, use or disclosure to third parties without express
authority is strictly forbidden.
c ABB Schweiz AG 2009
tolerances
ISO 2768-2 Schweiz AG 3BHS581347_E01 Sheet no:
1
1 2 3 4 5 0 6 50 7 100 8 9 10 11 12
60/616
ABB code:1 3AFP9155705 ver: B 2 3 4 5 6 7 8
PLANT: UN1020 MAN OEM 1CH

B
AVR-SYSTEM
C
UNITROL 1020, 1CH

AVR System assembled on plate. Designed for up to 20A
Forwarding and/or the duplicating of this document without the express permission of ABB is forbidden.
ABB reserves all rights to this document and to the information and topics contained in it.
D
This also applies to any possible claims to copyright or patents.
FOR INFORMATION
FOR APPROVAL
FOR FABRICATION
AFTER DELIVERY
F
AFTER COMMISSIONING
H 15.01.2019 Issued S.Gentner Office resp. Title MAN OEM 1CH
15.01.2019 Check 1 R.Moeckli COVER SHEET 5126
Revision
IAPG-E
< > 002 Page No. pp.
3BHS581347E20
Check 2
15.01.2019 Released S.Gentner Der. from Doc. Format A3 001 10
61/616
ABB code:1 3AFP9155705 ver: B 2 3 4 5 6 7 8
Page Title Revision Page Title Revision

No. No.
/001 COVER SHEET E F G H

A
/002 LIST OF CONTENTS E F G H
/010 BLOCK DIAGRAM G B C D
/110 MAIN CIRCUIT E G C D
/120 MEASUREMENT CIRCUIT A B C D
/200 DIGITAL INPUTS & OUTPUTS E F G H
/210 ANALOG INPUTS & OUTPUTS G B C D
/900 LIST OF TERMINALS E G C H
/960 LIST OF COMPONENTS COVER SHEET - B D
/961 LIST OF COMPONENTS E G C H
B
E Issued S.Gentner Office resp. Title MAN OEM 1CH

F Check 1 R.Moeckli LIST OF CONTENTS 5126
Revision
IAPG-E 001 < > 010 Page No. pp.

3BHS581347E20
G Check 2
H Released S.Gentner Der. from Doc. Format A3 002
62/616
ABB code:1 3AFP9155705 ver: B 2 3 4 5 6 7 8
A PTNET
UAUX
UNET
GEN CB GENERATOR VOLTAGE SENSING
RELAY
INTERFACE
-K..
B
-V05 DIGITAL
-K07 -R01 INPUTS AND
FF OUTPUTS
-K..
-Q11 -V04
EXCITATION POWER
C 2CT
IGEN1
Uaux
Unet
-G10 IG UG Vdig
POWER CPU
PART
AVR+FCR
AUTO/PF OR
AUTO/VAR
SYNCH
FBIAS
D
DIGITAL I/O
Analog I/O
MODBUS MODBUS
(TO DCS)
PMG USB
ETHERNET
E
-V01/-V02/-V03 EXC. CAP.
G 3
E
~
UE
-K11
-C01
3~
-K06
3CT -F02
CMT 1000
F
G Issued S.Gentner Office resp. Title MAN OEM 1CH

B Check 1 R.Moeckli BLOCK DIAGRAM 5126
Revision

3BHS581347E20
C Check 2
D Released S.Gentner Der. from Doc. Format A3 010
63/616
ABB code:1 3AFP9155705 ver: B 2 3 4 5 6 7 8
-Q11
-G10
/110.E6
EXCITATION POWER SUPPLY -V04 10
-X1 6 L1 P 16 PWR L1
from PMG or ~
1
/900.A3
2
Voltage transformer
L2
7 ~ 14 PWR L2
A 9
3
4
-C01 1
L3 N
8 ~ 12 PWR L3
8 2
6
5
-X1 16 15 AUX L1/DC+ AC
U AUX 17
/900.B3 13 AUX L2/DC-
11 AUX L3
24V DC DC
Supply
PE1 17
PE
PE2 -W100
1
B PE3
-G10:21 /200.D8
-X1 18 -R01
14
-V05
/900.B3 1 5
11
L1 P
1 2 ~ -K11 2 -K11 6
12
(only optional, FIELD L2 /200.F2 /200.F2

if required) FLASHING ~
19 L3 N
24
24V DC ~ /200.F2 /200.F2

4 8
21
Supply -K11 -K11

22
3 7
-K07
/200.F5
-V02
L1 P -X1 4 EXCITER
12 14 22 24 32 34 42 44 ~
L2
/900.A3 FIELD
-K06 11 ~
21 /200.F5
31 /200.F5
41 L3 N
/200.E5 /200.F5
~
-V03 +
D P
~
L1
L2
-V01 ~ -
L1 P N L3
~ ~
L2
~
(only optional, L3 N -X1 5
~
not required if /900.A3
PMG is utilized)
-F02
IG BOOST
-X1 1
ECL-10
/900.A3
E 2
4 -Q11
3 5
6
7
1 2
8 /110.A2 I>
3 4
9 /110.A2 I>
5 6
L3 10 /110.A2 I>
L2 11
13 14
L1 12
21 22
13 /200.D3
F

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L1
L2 -G10 /110.B3
MEASUREMENT
L3 -X1 11 7 ML1
/900.B3 12 6 ML2 -G10 /110.B3
PT MACH
13 5 ML3 77
GND
76
C 5V
-X1 14 4 NW1 75
CAN +
PT NET 15 3 NW3 PT NET 71
-
73
9 2 MC2+ 72
1 MC2- CT MACH 74
10 EIA
-
485 70
+
RJ45 RJ45
ETHERNET
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AVR AUTOMATIC SPARE ALTERNATOR SYNC EMERGENCY
AVR SYNCHRONIZATION INPUTS CB DEAD BUS EXC
TRIP RELEASE CLOSED ENABLE OFF
*) *)
A /210.A1
-X1 29 29 29 29 29 29 20 21 22 23 24 25 26 27 28
/900.D3
12 14 12 14
-K03 11 -K05 11
B /200.F4 /200.F4
-K12
/200.F7
A1
A2
12 14
-K01 11
/200.F3
C
22 24
-K12 21
/200.F7
-K01 -K11.1 -K03 -K05 -K06 -K07
/200.F3 /200.F3 /200.F4 /200.F5 /200.E5 /200.F6
A1
A1
A1
A1
A1
A1
A1
2
-R11
12 14 12 14
U
A2
A2 -K11
A2
A2
A2
A2
A2
1
/200.F2
21 11 -K12 11
-Q11 22 -K11.1 /200.F7
24 22 /200.F3
D /110.F6
21 -K11.1
/200.F3
-U01:A2 /210.B5
-X1:PE3 /110.B2
29
28
25
24
23
22
37
36
35
34
31
30
/110.B3
/110.B3
/110.B3
21
39
38
33
32
27
26
20
+24V
+24V
+24V
+24V
+24V
+24V
DGND
DGND
DGND
NO. TYPE TYPE DESCRIPTION POLARITY
Vdig
Vdig
Vdig
-G10
-G10
-G10
DIO1
DIO2
DIO3
DIO4
DIO5
DIO6
DIO7
DIO8
DI10
DI11
DI12
DI9
E DIO1 OUT FCB OPEN NOR.
DIO2 OUT FCB CLOSE NOR.
DIO3 OUT SUPERVISION TRIP INV.
-K06 *) signals only required, if synchronization function of AVR is utilized
DIO4 IN EXTERNAL ALARM NOR. /200.C5
DIO5 OUT CLOSE CB COMMAND NOR. 12
11
DIO6 OUT BOOST NOR. /110.D2 14
DIO7 OUT VOLTAGE RELAY NOR. -K11 22
-K11.1 -K01 -K03 -K05 21 -K07 -K12
DIO8 IN NOR. /200.D3 /200.C3 /200.C2 /200.C3 /200.C5 /110.D3 24 /200.C5 /200.B8
DI9 IN GEN CB CLOSED NOR. 1 2 12 12 12 12 32 12 12
/110.B6 11 11 11 11 31 11 11
DI10 IN SYNC DEAD BUS ENABLE NOR. 3 4 /200.D7 14 /200.C2 14 /200.B4 14 /200.B5 14 /110.D3 34 /110.B2 14 /200.D7 14
/110.C6
DI11 IN FCB IS CLOSED NOR. 5 6 22 22 22 22 42 22 22
/110.B7 21 21 21 21 41 21 21
F DI12 IN EMERGENCY EXC OFF NOR. 7 8 /200.D3 24 24 24 24 /110.D3 44 /110.C2 24 /200.C2 24
/110.C7

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VOLTAGE VOLTAGE
FBIAS
INCREASE DECREASE
**) **) -10...+10V
*)
A /200.A8
-X1 33 34 31 32
/900.D3
No. TYPE DESCRIPTION POLARITY

AI1+ AN IN NOR.
AI1- AN IN NOR.
B
AI2+ AN IN NOR.
AI2- AN IN NOR.
AI3+ DIG IN INCREASE NOR.
AI3- DIG IN DECREASE NOR.
A01 AN OUT NOR. /200.D4 -K11.1:21
A02 AN OUT FBIAS NOR.
-U01 A1
-U02 A1
A2
A2
C
13+
13+
14
14
D
41
40
43
42
49
48
51
50
53
52
Ref. SUPPLY FOR ANALOG
47
BRP GND pos. 46

45
BRN GND neg. 44
/110.B3
/110.B3
/110.B3
/110.B3
/110.B3
/110.B3
ARP +10V
ARN -10V
+
+
-
-
A02 #
A01 #
#
-G10
-G10
-G10
-G10
-G10
AI1
AI2
AI3
-G10
**) optional, for external synchronization *) signal only required, if synchronization function of AVR is utilized
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INTERNAL EXTERNAL
SIGNAL DESIGNATION SIGNAL DESCRIPTION DATA CLASS EXTERNAL TERMINAL TYP UL-FILE NUMBER
DISCONNECT
A /110.E1 -X1 1 L1 xxMKA01CE004A BOOST CIRCUIT 1

/110.E2 2 L2 xxMKA01CE004B
/110.E2 3 L3 xxMKA01CE004C
/110.D7 4 F1+ EXCITATION FIELD 1 PHOENIX ST6 E60425
xxMKA01CE005
/110.E7 5 F1-
/110.A1 6 L1 xxMKA01CE011A EXCITATION POWER 3x250VAC max. 1
/110.A2 7 L2 xxMKA01CE011B 1x250VAC max.
/110.A2 8 L3 xxMKA01CE011C 50Hz
/120.C2 9 L2 CURRENT SENSING 1A/5A 1
xxMKA01CE003B
/120.D2 10 COM
/120.C2 11 L1 xxMKA01CE012A GENERATOR VOLTAGE SENSING 3x250VAC max. 1 X
/120.C2 12 L2 xxMKA01CE012B PHOENIX ST6 E60425
B
/120.C2 13 L3 xxMKA01CE012C
/120.C2 14 L1 PT NET MAX 250V/0.2VA 1 X
/120.C2 15 L3
/110.A1 16 + 24VDC CONTROL VOLTAGE 24V DC 1 X
/110.B2 17 - PHOENIX ST6 E60425
/110.B1 18 + 24VDC FIELD FLASHING VOLTAGE 24V DC 1 X
/110.C2 19 -
/110.B1 PE1
/110.B2 PE2 GROUNDING PHOENIX ST6-PE E60425
/110.B2 PE3
/200.A3 20 + xxCJN01EU100-XJ05 AVR TRIP <250VAC DC 2
C /200.A4 21 - <50W**
/200.A5 22 + xxCJN01EU100-YA95 AVR AUTOMATIC SYNCHRONIZATION RELEASE CB <250VAC DC 2
/200.A5 23 <50W**
/200.A5 24
/200.A6 25 SPARE INPUT 24V DC, 300mA PHOENIX ST2,5 E60425
/200.A7 26 xxBAC01GS003-XB01 ALTERNATOR CB IS CLOSED TO AVR 24V DC, 300mA
/200.A7 27 xxCJN01EU100-YJ10 SYNC DEAD BUS ENABLE 24V DC, 300mA 2
/200.A8 28 EMERGENCY EXC OFF 24V DC, 300mA
/200.A1 29 24VDC CONTROL VOLT. 24V DC
/200.A1 29
/200.A1 29
D /200.A1 29
/200.A1 29
/200.A1 29
30
/210.A7 31 2
xxCJN01EU100-XQ01 FBI AS -10...+10V
/210.A7 32
/210.A6 33 xxCJN01EU100-YJ07 VOLTAGE INCREASE 24V DC, 300mA
2
/210.A6 34 xxCJN01EU100-YJ08 VOLTAGE DECREASE 24V DC, 300mA

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B
LIST OF COMPONENTS
C
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COVER SHEET 900 < > 961 Page No. pp.
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PLANT LOCATION EQUIPMENT DESIGNATION TECHNICAL DATA ABB-IDENTNUMBER ABB-ASSEMBLY NUMBER UL-FILE NUMBER SHEET
-C01 CAPACITOR 1000uF 3BHE040190R0001 3BHE044230R0010 E251846 3BHS581347E20/110
450VDC
A -F02 EXCITATION CURRENT LIMITER ECL-10 3BHE009426R0001 E325367 3BHS581347E20/110
-G10 UN1020 UN1020 3BHE030579RXXXX E251846 3BHS581347E20/110
-K01 RELAY 40.52.7.024 3BHE007680R0001 E81856 3BHS581347E20/200
24VDC
24VDC
24VDC
-K06 CONTACTOR 56.34.9.024 3BHE007681R0002 E81856 3BHS581347E20/200
B 24VDC
24VDC
-K11 CONTACTOR AL26-40-00 1SBL243201R8100 E39231 3BHS581347E20/200
24VDC
-K11.1 RELAY 40.52.7.024 3BHE007680R0001 E81856 3BHS581347E20/200
24VDC
24VDC
-Q11 M.C.B. MS325 1SAM150000R0012 E137861 3BHS581347E20/110
C
12,5..16A
+AUX.1SAM101901R1
-R01 RESISTOR 25W 3BHE050781R0001 NOT APPLICABLE 3BHS581347E20/110
4,7 Ohm, 5%
-R11 VARISTOR RV5/50 1SBN050010R1000 NOT APPLICABLE 3BHS581347E20/200
24..50V
AC/DC
U
-U01 OPTOCOPLER PLC-OSC-24DC/48DC/100 3BHE024500R0024 E172140 3BHS581347E20/210
D 24VDC/3..48VDC
-U02 OPTOCOPLER PLC-OSC-24DC/48DC/100 3BHE024500R0024 E172140 3BHS581347E20/210

24VDC/3..48VDC
-V01 DIODE BRIDGE VUO 35-16 N07 3BHE040875R1600 3BHE040875R0010 E251846 3BHS581347E20/110
35A E72873
1600V
35A E72873
E 1600V
35A E72873
1600V
-V04 DIODE BRIDGE 36MT120 3BHE043052R0001 E300359 3BHS581347E20/110
35A
1200V
-V05 DIODE BRIDGE 36MT120 3BHE043052R0001 E300359 3BHS581347E20/110
35A
F 1200V

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AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13

ABB ref. 1637HH101-111
6.
Manual
ABB
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Section 6 - Manual
Table of Contents
1. Introduction ........................................................................................................ 1
1.1. General information ................................................................................... 1
1.2. Important note ........................................................................................... 1
1.3. Warranty .................................................................................................. 2
1.4. Site conditions .......................................................................................... 2
2. Transport and storage ............................................................................................ 3
2.1. Transport and unpacking ............................................................................. 3
2.1.1. Protective measures prior to transport .................................................. 3
2.1.2. Lifting the machine .......................................................................... 3
2.1.3. Lifting of unpacked machine ............................................................. 3
2.1.4. Checks upon arrival and unpacking ..................................................... 4
2.2. Storage .................................................................................................... 4
2.2.1. Short term storage (less than 2 months) ............................................... 4
2.2.2. Long term storage (2-6 months) ......................................................... 5
2.2.3. Very long term storage (over 6 months) ............................................... 6
2.2.4. Regular checks during storage ........................................................... 7
2.2.5. Storage and care after installation ....................................................... 7
3. Installation and alignment ...................................................................................... 8
3.1. Preparations for installation ......................................................................... 8
3.1.1. General ......................................................................................... 8
3.1.2. Check of foundation ........................................................................ 9
3.2. Installation ............................................................................................... 9
3.3. Alignment .............................................................................................. 10
3.3.1. Rough levelling ............................................................................. 10
3.3.2. Rough axial alignment .................................................................... 11
3.3.3. Air gap check ............................................................................... 12
3.3.4. Alignment .................................................................................... 13
3.3.5. Final alignment ............................................................................. 14
3.3.6. Correction for thermal expansion ...................................................... 16
3.4. Final inspection and installation .................................................................. 16
3.4.1. Covers and enclosures .................................................................... 16
4. Mechanical and electrical connections .................................................................... 17
4.1. General .................................................................................................. 17
4.2. Electrical connections ............................................................................... 17
4.2.1. General information ....................................................................... 17
4.2.2. Connection of main power cables ..................................................... 17
4.2.3. Earthing connection ....................................................................... 18
4.2.4. Insulation distances of main power connections ................................... 19
4.2.5. Connection of auxiliaries and instruments .......................................... 20
4.2.6. Automatic Voltage Regulator (AVR) ................................................. 20
4.2.7. Installation of Automatic Voltage Regulator (AVR) .............................. 22
5. Commissioning .................................................................................................. 23
5.1. General .................................................................................................. 23
5.2. Check of mechanical installation ................................................................. 23
5.3. Check of electrical installation .................................................................... 24
5.4. Insulation resistance measurements ............................................................. 24
5.5. Automatic Voltage Regulator (AVR) ............................................................ 25
6. Operation .......................................................................................................... 26
6.1. General .................................................................................................. 26
6.2. Normal operating conditions ...................................................................... 26
6.3. Protection of synchronous generators ........................................................... 27
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6.4. Start-up procedure .................................................................................... 27

6.4.1. Starting ........................................................................................ 27
6.4.2. Start interlocking ........................................................................... 28
6.5. Continuous supervision ............................................................................. 28
6.6. Shut down procedures ............................................................................... 28
6.6.1. Shut down .................................................................................... 29
7. Maintenance ...................................................................................................... 30
7.1. Preventive maintenance ............................................................................. 30
7.2. Safety precautions .................................................................................... 30
7.3. Maintenance program ............................................................................... 31
7.3.1. Mandatory maintenance program ...................................................... 33
7.4. Maintenance of general construction ............................................................ 37
7.4.1. The tightness of fastenings .............................................................. 37
7.4.2. Vibration and noise ........................................................................ 41
7.4.3. Rotor construction control ............................................................... 41
7.4.4. Checks during running of the machine ............................................... 41
7.5. Maintenance of lubrication system and bearings ............................................. 45
7.5.1. Lubrication ................................................................................... 45
7.5.2. Sleeve bearings ............................................................................. 47
7.5.3. Oil leakage of sleeve bearings .......................................................... 48
7.5.4. Bearing insulation resistance check ................................................... 52
7.5.5. Bearing clearance measurements ...................................................... 53
7.6. Maintenance of stator and rotor winding ....................................................... 53
7.6.1. Particular safety instructions for winding maintenance .......................... 54
7.6.2. Timing of the maintenance .............................................................. 55
7.6.3. The correct operating temperature ..................................................... 55
7.6.4. Insulation resistance – measurement and minimum values ..................... 55
7.6.5. General notes regarding the measurement: .......................................... 57
7.6.6. Minimum values for insulation resistance ........................................... 57
7.6.7. Polarization index .......................................................................... 62
7.6.8. High voltage test ........................................................................... 62
7.6.9. Fault searching methods .................................................................. 63
7.6.10. Tan delta-measurements ................................................................ 63
7.6.11. PD measurements ........................................................................ 63
7.6.12. Surge comparison test ................................................................... 64
7.6.13. Visual winding inspection .............................................................. 64
7.6.14. Cleaning the windings .................................................................. 65
7.6.15. Drying ....................................................................................... 68
7.6.16. Partial discharges ......................................................................... 69
7.6.17. Varnishing of the windings ............................................................ 70
7.6.18. Other maintenance operations ........................................................ 70
7.7. Maintenance related to electrical performance, excitation, control, and
protection ..................................................................................................... 70
7.7.1. Exciter insulation resistance measurement .......................................... 71
7.7.2. Protection trips .............................................................................. 71
7.7.3. Maintenance of Automatic Voltage Regulator (AVR) ............................ 71
7.7.4. Pt-100 resistance temperature detectors .............................................. 72
7.7.5. Insulation resistance measurement for auxiliaries ................................. 74
7.7.6. Diode fault ................................................................................... 74
7.8. Maintenance related to thermal performance and cooling system ....................... 75
7.8.1. Cooling System ............................................................................. 75
8. Troubleshooting ................................................................................................. 77
8.1. Mechanical performance ........................................................................... 78
8.2. Lubrication system and bearings ................................................................. 79
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8.2.1. Lubrication system and sleeve bearings .............................................. 79

8.3. Thermal performance ................................................................................ 80
8.3.1. Thermal performance, open air cooling system .................................... 80
8.4. Electrical performance .............................................................................. 81
8.4.1. Electrical performance and excitation system of generators .................... 81
9. Global Technical Support Center Finland and life cycle services .................................. 82
9.1. The Global Technical Support Center Finland ................................................ 82
9.1.1. Site Services ................................................................................. 82
9.1.2. Spare Parts ................................................................................... 82
9.1.3. Support and Warranties ................................................................... 82
9.1.4. Support for Service Centres and partners ............................................ 83
9.1.5. Global Technical Support Center Finland contact information ................ 83
9.2. Spare parts .............................................................................................. 83
9.2.1. General spare part considerations ...................................................... 83
9.2.2. Periodic replacement of parts ........................................................... 83
9.2.3. Need for spare parts ....................................................................... 84
9.2.4. Selection of the most suitable spare part package ................................. 84
9.2.5. Typical recommended spare parts in the individual sets ......................... 84
9.2.6. Order information .......................................................................... 86
10. Disposal and recycling instructions ....................................................................... 87
10.1. Introduction .......................................................................................... 87
10.2. Average material content .......................................................................... 87
10.3. Recycling of material required for transport ................................................. 87
10.4. Recycling of the complete machine ............................................................ 87
10.4.1. Dismantling of the machine ........................................................... 87
10.4.2. Frame, bearing housing, covers and fan ............................................ 88
10.4.3. Components with electrical insulation .............................................. 88
10.4.4. Permanent magnets ...................................................................... 88
10.4.5. Hazardous waste .......................................................................... 89
10.4.6. Landfill waste ............................................................................. 89
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Section 6 - Manual
Chapter 1 Introduction
1.1. General information

This User's Manual contains information on the transport, installation, operation and maintenance
of the synchronous machine manufactured by ABB.
This manual provides information regarding all aspects of operation, maintenance and supervision
of the machine. Careful study of the contents of this manual and other machine related
documentation before any actions are taken is necessary to ensure proper functionality and a long
lifetime of the machine.
Actions shown in this manual are only to be performed by trained personnel authorized by the
owner of the equipment and with previous experience in similar tasks or by trained personnel
under supervision of personnel with previous experience in similar tasks.
This document and parts thereof must not be reproduced or copied without the express written
permission of ABB, and the contents thereof must not be imparted to a third party nor be used
for any unauthorized purpose.
ABB constantly strives to improve the quality of the information provided in this User's Manual,
and will welcome any improvement suggestions. For contact information, see Chapter 9.1, The
Global Technical Support Center Finland.
NOTE: These instructions must be followed to ensure safe and proper installation,
operation and maintenance of the machine. They should be brought to the
attention of anyone who installs, operates or maintains this equipment. Ignoring
the instruction invalidates the warranty.
1.2. Important note

The information in this document may sometimes be of a general nature and applicable to various
machines produced by ABB.
Where a conflict exists between the contents herein and the actual machinery supplied, the user
must either make an informed engineering judgement as to a course of action or, if any doubt
exists, contact ABB.
The safety precautions shown in Section 1, Introduction must be observed at all times.
Safety is dependent on the awareness, concern and prudence of all those who operate and service
machines. While it is important that all safety procedures be observed, care near machinery is
essential - always be on your guard.
NOTE: To avoid accidents, safety measures and devices required at the installation
site must be in accordance with the instructions and regulations stipulated for
safety at work. This applies to general safety regulations of the country in
question, specific agreements made for each work site and safety instructions
included in this manual and separate safety instructions delivered with the
machine.
Introduction - 1
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Section 6 - Manual
1.3. Warranty
In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages
of any nature or kind arising from the use of this document, nor shall ABB be liable for incidental
or consequential damages arising from use of any software or hardware described in this document.
The warranty issued covers manufacturing and material defects. The warranty does not cover any
damage caused to the machine, personnel or third party by improper storage, incorrect installation
or operating of the machine. The warranty conditions are in more detail defined according to
Orgalime S2000 terms and conditions.
NOTE: The warranty issued is not valid, if the operation conditions of the machine
are changed or any changes in the construction of the machine, or repair work
to the machine have been made without prior written approval from the ABB
factory, which supplied the machine.
NOTE: Warranty period and other project specific warranty terms are specified in
commercial contract.
For contact information, see the back page of this User's Manual. Please remember to provide the
serial number of the machine when discussing machine specific issues.
1.4. Site conditions

This machine is to be used on a site with environmental conditions according to ABB specifications
(listed in Section 1, Introduction and Section 3, Technical Specification).
Introduction - 2
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Section 6 - Manual
Chapter 2 Transport and storage
2.1. Transport and unpacking
2.1.1. Protective measures prior to transport

The following protective measures are taken before delivery of the machine from the factory. The
same protective measures should be taken, whenever the machine is moved:
• All synchronous machines delivered as a unit are provided with an axial movement locking
device protecting the bearings against damages during transport. The locking device must be
attached whenever the machine is transported.
• Machined metal surfaces, such as the shaft extension, are coated with an anti-corrosive coating
before delivery.
• The bearings are flooded with oil during the tests prior to delivery. This gives sufficient
protection against corrosion.
During shipping the machine should be placed under deck.
2.1.2. Lifting the machine

Before the machine is lifted, ensure that suitable lifting equipment is available and that personnel
is familiar with lifting work. The weight of the machine is shown on the rating plate, dimension
drawing and packing list.
NOTE: Use only the lifting lugs or eyes intended for lifting the complete machine.
Do not use any small additional lifting lugs or eyes available, as they are there
only for service purposes.
NOTE: The center of gravity of machines with the same frame may vary due to
different outputs, mounting arrangements and auxiliary equipment.
NOTE: Check that eyebolts or the lifting lugs integrated with the machine frame are
undamaged before lifting. Damaged lifting lugs must not be used.
NOTE: Lifting eyebolts must be tightened before lifting. If needed, the position of
the eyebolt must be adjusted with suitable washers.
2.1.3. Lifting of unpacked machine

Lifting must be performed with great care and using slings long enough to assure the lifting angle
requirements. If the requirements are not met, there is a risk of damage. See Figure 2-1, Lifting
an unpacked machine For more details, see the lifting drawing in Section 4, Mechanical Drawings.
NOTE: The machine must be lifted from its frame. Do not attempt to lift the machine
from the top cover!
Transport and storage - 3

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Section 6 - Manual
Figure 2-1 Lifting an unpacked machine
2.1.4. Checks upon arrival and unpacking
2.1.4.1. Check upon arrival

Inspect the machine and the package immediately upon arrival. Any transport damage must be
photographed and reported immediately, i.e. within less than one (1) week after arrival, if the
transport insurance is to be claimed. It is, therefore, important that evidence of careless handling
is checked and reported immediately to the transport company and the supplier. Use checklists
in Section 9 COMMISSIONING REPORT.
A machine that is not installed immediately upon arrival must not be left without supervision or
without protective precautions. For more details, see Chapter 2.2, Storage.
2.2. Storage
2.2.1. Short term storage (less than 2 months)

The machine should be stored in a proper warehouse with a controllable environment. A good
warehouse or storage place has:
• A stable temperature, preferably in the range from 10 ºC (50 °F) to 50 ºC (120 °F). If the
anti-condensation heaters are energized, and the surrounding air is above 50 ºC (120 °F), make
sure that the machine is not overheated.
• Low relative air humidity, preferably below 75 %. The temperature of the machine should be
kept above dew point to prevent moisture from condensing inside the machine. If the machine
is equipped with anti-condensation heaters, they should be energized. Verify the operation of
the anti-condensation heaters periodically. The anticondensation heaters shall be de-energised
when air temperature inside the machine enclosure exceeds + 40 ºC. If the machine is not
equipped with anti-condensation heaters, an alternative method of heating the machine and
preventing moisture from condensing in the machine must be used.
• A stable support free from excessive vibrations and shocks. If vibrations are suspected to be
too high, the machine should be isolated by placing suitable rubber blocks under the machine
feet.
• Air which is ventilated, clean and free from dust and corrosive gases.
• Protection against harmful insects and vermin.

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If the machine needs to be stored outdoors, the machine must never be left ‘as is’ in its
transportation package. To store the machine outdoors:
1. Take the machine out from its plastic wrap.
2. Cover the machine to prevent rain from entering it. The cover should allow ventilation of
the machine.
3. Place the machine on at least 100 mm (4”) high rigid supports. This prevents moisture from
entering the machine from below.
4. Provide with good ventilation. If the machine is left in its transportation package, make large
enough ventilation holes in the package.
5. Protect from harmful insects and vermin.
2.2.2. Long term storage (2-6 months)

In addition to the measures described in Chapter 2.2.1, Short term storage (less than 2 months),
some extra measures needs to be taken depending on whether the machine is stored indoors or
outdoors.
NOTE: Be careful not to damage the seals or the bearings.
Storage indoors
To store the machine indoors:
1. If the machine is stored in its transportation package, make big enough holes on the sides of
the transportation package so that the D-end and ND-end of the machine are accessible.
2. Protect the shaft and the sealing points, as well as all bearing parts against corrosion. Shaft
and bearing seals should be treated with an anti-corrosive agent (e.g. LPS 3, Holt Lloyd,
USA). The bearing should be filled with protective oil, for example
- Esso: Rust-Ban 623
- Gulf: Gulf No-Rust Engine Oil Grade 2
- Mobil: Mobilarma 524
- Shell: Shell Ensis Engine Oil 20
3. If the protection made by the manufacturer has been removed, protect the unpainted surfaces
such as shaft extensions, coupling halves and jacking screws with suitable anti-corrosion
agent.
4. If the machine has been delivered in fully assembled condition, turn the rotor approximately
10 revolutions once per every 3 months to maintain a protective oil film on the bearing
surfaces. Remove any possible transport locking devices before turning the rotor.
NOTE: Transport lockings are heavy weight parts. In order to remove

transport lockings, support the parts with lifting gear before
loosening or removing any screws.

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5. Fill self-lubricated bearings with oil, or connect flood lubricated bearings to the lubrication
system. If this cannot be done, the bearing shells should be taken out, see Storage outdoors.
Storage outdoors
To store the machine outdoors:
1. Take all the measures described in Storage indoors.
2. Cover the machine completely with a big enough waterproof cover.
3. Remove the side and end covers of the machine.
4. Push strong cardboard pieces into the air gap between the main machine stator and rotor so
that the rotor may be supported by the stator.
5. Dismount the bearing instruments.
6. Dismount the seals and the upper parts of the bearing housings.
7. Remove the upper parts of the bearing shells and dismount the eventual oil rings.
8. Lift the rotor up (approximately 0.5 mm) until the bearing shells do not carry the weight of
the rotor.
9. Turn the lower bearing shells 180 º over the shaft and remove them.
10. Lower the rotor so that it rests on the stator (cardboard pieces in between).
11. Protect the bare shaft surfaces and shells with anti corrosive agent.
12. Mount the bearing housings and seals (seals have to be loosened) and protect the seals with
anti-corrosion agent.
13. Store the bearing shells in a clean and dry place.
2.2.3. Very long term storage (over 6 months)

Clean all the protected surfaces listed in Chapter 2.2.1, Short term storage (less than 2 months)
and Chapter 2.2.2, Long term storage (2-6 months), and renew the anti-corrosive treatment every
12 months. Otherwise follow the instructions for shorter storage periods.

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2.2.4. Regular checks during storage

The following checks should be made regularly during storage.
Every month:
• Check that the anti-condensation heaters are working.
• Check that the ventilation works.
Every 3 months:
• Check the insulation resistance, see Chapter 7.6.4, Insulation resistance – measurement and
minimum values
• Check that there is no corrosion on the surfaces. If corrosion is observed, remove the corrosion
and protect the surfaces.
• Check that the anti-corrosion agents have not cracked.
Every 6 months:
• Dismount the bearing housing upper cover and check the shaft and the bearing housing
anti-corrosion protection.
2.2.5. Storage and care after installation

If the machine will not be in operation for a longer period of time after installation, the same
measures as in Chapter 2.2.1, Short term storage (less than 2 months) should be applied. Remember
to rotate the shaft 10 revolutions at least every 3 months. Self-lubricated bearings must be filled
with oil.

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Chapter 3 Installation and alignment
3.1. Preparations for installation
3.1.1. General
Good planning and preparation results in correct installation, assures safe running conditions and
maximum accessibility.
During installation, general as well as local safety instructions must be followed.
NOTE: Install anti-condensation heaters to keep the machine interior dry when there
is a risk of condensation.
NOTE: Protect the machine against dust and rain.
NOTE: During/before the installation transport locking devices needs to be removed.

Locking parts are heavy weight parts which need to be supported with lifting
gear before loosening or removing any screws.
Tools and materials

Suitable materials for set-up and shimming as well as other auxiliary tools for installation are
normally not included in the ABB delivery. Auxiliary tools for installation are to be supplied by
the customer.
The following should be available on site if required:
• attachments for gauges, extension brackets and other alignment tools
• a lever for turning the rotor
• other auxiliary tools and materials for the installation, such as hydraulic jacks and bracket
plates with adjusting screws
• for suitable oil qualities, see Chapter 7.5.1, Lubrication.
Pouring oil into the bearings

Before turning the rotor, suitable bearing oil must be filtered through a 10 micrometer mesh, and
poured into the bearings.
To pour oil into the bearings:
1. Turn the rotor using a lever.
2. Pour oil continuously into the bearings at both ends of the machine while turning the rotor,
see Figure 3-1, Pouring oil into the bearings.
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Figure 3-1 Pouring oil into the bearings
General tightening torques

General tightening torques for screws are given in Chapter 7.4.1, The tightness of fastenings. Use
these values if no specific tightening torques are given in this manual or in the mechanical and
electrical drawings (see Section 4, Mechanical Drawings and Section 5, Electrical Drawings).
3.1.2. Check of foundation

The structural design of the foundation is not included in the ABB scope, and the customer or a
third party is therefore responsible for this.
The installation of the machine should be planned as early as possible. Before lifting the machine
onto the foundation:
• Check that the position of the anchoring or fixing holes and the height of the foundation are
in agreement with corresponding measurements on outline and foundation drawings in Section
4, Mechanical Drawings.
• Check that the foundation is flat. If any inclination has been agreed upon, the permissible
inclination must be stated on the installation drawing.
• Sweep or vacuum-clean the foundation some days before installation.
3.2. Installation
The machine is normally transported and lifted as one ready assembled unit onto the foundation,
see Section 4, Mechanical Drawings.
To install the machine:
1. Mount the coupling halves, if applicable.
2. Mount the machine on the foundation.
3. Level and align the machine roughly in axial and horizontal directions.

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4. Align and couple the rotor with the driven machine.
5. Fasten the machine initially to the foundation.
6. Check air gaps and adjust as necessary.
7. Re-check the alignment. Fine adjust if necessary.
8. Tighten and lock bolts and install dowel pins.
9. Install accessories.
More detailed instructions for installation are given in the following chapters or in instructions
supplied by driven/driving machine manufacturer.
Bearing sealings may have been loosened for transportation. Check the sealings and, if necessary,
re-align them (see bearing documentation is Section 7, Accessory information).
3.3. Alignment
In order to ensure a long and satisfactory lifetime of both the driving and driven machine, the
machines have to be properly aligned to each other. This means that the radial, as well as the
angular deviation between the two shafts of the machine has to be minimized. The alignment must
be performed with great caution because alignment errors will lead to bearing and shaft damages.
Before alignment remove the transport locking device according to the instructions in the Transport
Locking drawing in Section 4, Mechanical Drawings. The transport locking device is normally
painted red.
3.3.1. Rough levelling

To rough level the machine:
1. Center the rotor (axially) to the middle of the end float of the drive end bearing.
2. Check that the distance ET is the same as the value stamped above the D-end bearing.
See 3-3, Typical marking of ET dimension and Section 4, Mechanical Drawings.
3. Remove the anti-corrosive coating from metal surfaces that have to be uncoated during
normal operation.
4. Check the coupling instructions and fit. Preheat the coupling hub as necessary and mount it
on the machine shaft.
5. Lift the machine up and move it onto the bed plate.
6. Align the machine visually and put pieces of sheet metal below the jacking screws to protect
the bed plate surface.
7. Turn the jacking screws until they carry the weight of machine.
Check that the machine is radially and axially leveled by placing a spirit level on the horizontal
surfaces of the frame and rotor shaft as shown in Figure 3-2, Placement of the spirit level. Make
adjustments by placing shims under the feet. The machine must be supported by all feet.

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Figure 3-2 Placement of the spirit level
3.3.2. Rough axial alignment

The correct axial position of the rotor is shown by the magnetic center indicator above the shaft.
The position is correct when the tip of the indicator is in line with the machined groove on the
shaft.
The rotor is placed in the magnetic center position when the dimension ET is completed. Read
the correct distance in the inspection and test record in Section 8 under ET Dimension. The
dimension has also been punched on the D-end of the machine.
See Figure 3-3, Typical marking of ET dimension and Section 4, Mechanical Drawings for details.
If the rotor has axial float, check the mechanical center position of the rotor.
NOTE: The running center is not the same as the magnetic center because the
machine's radial cooling fan has an axial component that will affect the rotor
running position.
If there is no thrust bearing, the machine cannot withstand any axial force from the driven machine.
In this case, the axial force must be carried by the driven machine, and the coupling must be of
limited axial float type.
If there is an axially locating bearing on the machine, make sure that continuous free axial
movement is possible between the coupling halves (excluding rigid couplings) in order to permit
thermal expansion of the machine shaft without damaging the bearings.
When the machine stands axially in its right position, leave all adjusting jacking screws only
lightly tightened.

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Figure 3-3 Typical marking of ET dimension
3.3.3. Air gap check

To check the air gap of the electrical machine between the stator and the rotor:
1. Remove the side covers, or where applicable, the end covers of the machine frame.
2. Push a wedge-shaped measuring strip in the air gap at the middle of one pole in four
symmetrically chosen rotor positions.
3. Turn the rotor correspondingly.

Where applicable, there is a hole in the fan through which the measuring can be done.
NOTE: Make sure that the bearings are filled with oil before turning the
rotor.
NOTE: Centering of the rotor, i.e. the air gap, is adequate when a single measured
value does not deviate more than 10 percent from the mean value.
To adjust the air gap of the stator and the rotor of the electrical machine:
1. Loosen the bolts retaining the bearing housing to the bearing support.
2. Remove the dowel pins.
3. Move the complete bearing housing.

Adjustment is finalised by adding or removing shims between the bearing housing and the
bearing housing support, i.e. the pedestal.
After the air gap of the stator and the rotor of the electrical machine have been checked and
adjusted, the air gap between the exciter stator and rotor, at the ND-end of the machine, has to be
checked in four symmetrically chosen positions. The exciter air gap is adjusted by moving the
exciter stator.

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Figure 3-4 Air-gap between stator and rotor
After the adjustment of the air gap, tighten all the fastening bolts, see Table 7-2, General tightening
torques 1. Verify the air gap once more where appropriate dowel pins are inserted.
3.3.4. Alignment
After the machine has been roughly positioned, as described in Chapter and 3.3.2, Rough axial
alignment, the final alignment can start.
NOTE: Alignment must be performed with great caution. Failure to do so can result
in serious vibrations and damage to both driving and driven machine.
The alignment is done in accordance with the recommendations given by the coupling manufacturer.
Parallel, angular and axial alignment of the machine is required. Some standard publications give
recommendations for coupling alignment, see for example BS 3170:1972 "Flexible couplings for
power transmission".
In accordance with common practice, parallel and angular misalignment should not exceed 0.05
- 0.10 mm and axial misalignment should not exceed 0.10 mm, see Figure 3-5, Definition of
misalignment . The corresponding run-out is 0.10 - 0.20 mm for parallel and angular misalignment,
and 0.20 for axial misalignment.

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Figure 3-5 Definition of misalignment

Parallel misalignment Δr
Angular misalignment Δb
Axial misalignment Δa
Definite alignment tolerances are impossible to state as many factors influence the tolerances.
Too large tolerances will cause vibration and may possibly lead to bearing or other damages.
Therefore, it is recommended to aim at as narrow tolerances as possible. Maximum permissible
misalignments are shown above. For definitions of misalignment, see Figure 3-5, Definition of
misalignment .
NOTE: The tolerances given by the coupling manufacturers indicate tolerances for
the coupling, not for the driving-driven machine alignment. The tolerances
given by the coupling manufacturer should be used as a guideline for the
alignment only if they are narrower than the maximum permissible
misalignments shown above.
3.3.5. Final alignment

To align the machine:
1. Make sure that the machine stands on its jacking screws.
2. Rotate the rotor and check the axial end float, see Chapter 3.3.2, Rough axial alignment.
NOTE: Lubricate the bearings at regular intervals during the final alignment
in accordance with Chapter 3.1, Preparations for installation.
3. Mount the alignment equipment. If gauges are used, it is practical to adjust the dial gauge
in such a way that approximately half of the scale is available in either direction. Check the
rigidity of the gauge brackets in order to eliminate the possibility of sag, see Figure 3-6,
Alignment check with gauges.

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Figure 3-6 Alignment check with gauges
4. Measure and note readings for parallel, angular and axial misalignment in four different
positions: top, bottom, right and left, i.e. every 90°, while both shafts are turned
simultaneously. Record the readings in the Commissioning Report in Section 9.
5. Align the machine vertically by turning the jacking screws or the adjustment screws, or by
jacking with hydraulic jacks.
To facilitate the alignment in the vertical plane, jacking screws are fitted to the feet of the
horizontal machine. See Figure 3-7, Vertical positioning of machine foot.
The alignment accuracy of the machine is sometimes affected by the thermal expansion of
its frame. See Chapter 3.3.6, Correction for thermal expansion.
Figure 3-7 Vertical positioning of machine foot
6. Measure the distance between the bottom of the machine feet and the bed plate and make
corresponding solid blocks or wedges or reserve a necessary number of shims.
7. Fit the solid blocks or shims under the stator feet. Slacken the jacking screws and tighten the
fixing bolts.
8. Check the alignment again. Make corrections if necessary.
9. Check the air gap of the machine and the exciter.
10. Draw up a record for future checks (Section 9, Check Lists).
11. Re-tighten the nuts and lock them by tack welds or hitting sufficiently hard with a center
punch.

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3.3.6. Correction for thermal expansion

Thermal expansion should be taken into account when aligning the machine. The temperature of
the machine is lower during installation than it will be during operating conditions. For this reason
the shaft centre is going to lie higher when the machine is in operation.
Depending on the type of coupling, the distance between the machine and the driven equipment
may have to be compensated because of thermal expansion.
The upward thermal expansion of the electrical machine can be estimated using the following
formula:
ΔH = a × ΔT × H [mm]
where a = 10 × 10-6 K-1
ΔT = 40 K
H = shaft height [mm]
Due to the thermal expansion of the electrical machine, the vertical movement of the shaft is
approximately 0.1 mm for each 10 °C difference in temperatures as illustrated in Figure 3-8, The
correlation between thermal expansion and machine temperature.
Figure 3-8 The correlation between thermal expansion and machine temperature
3.4. Final inspection and installation
3.4.1. Covers and enclosures

After the machine has been erected and aligned, and its accessories have been installed, check
carefully that no tools or foreign objects have been left inside the enclosures. Clean also any dust
or debris.
When installing the covers, check that all sealing strips are intact before mounting them.
Store alignment and assembly accessories together with the transport locking devices for future
use.

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Chapter 4 Mechanical and electrical connections
4.1. General
Mechanical and electrical connections are made after the installation and alignment procedures.
The mechanical connections include the connection of air ducts, water tubes and/or oil supply
system where applicable.
The electrical connections include the connection of main and auxiliary cables, earthing cables
and possible external blower motors.
In order to determine proper actions, see Section 4, Mechanical Drawings and Section 5, Electrical
Drawings.
NOTE: Additional installation holes or threads should never be drilled through the
frame, as this may damage the machine.
4.2. Electrical connections
4.2.1. General information

The safety information in Section 1, Introduction, Chapter 5 Safety Instructions (High-voltage
AC Machines) must be observed at all times. Study the connection diagrams delivered with the
machine before starting the installation, see Section 5, Electrical Drawings.
Before you start the installation:
• Verify that the supply voltage and the frequency are the same as the values indicated on the
rating plate of the machine and in Section 3, Technical Specification.
• Make sure that the sizes of input cables are adequate for the maximum load current and in
accordance with local standards.
• Make sure that cable terminations are of appropriate type and of correct size.
• Check the connections of all devices, such as temperature probes.
NOTE: Prior to installation it is important to check that the incoming cables are not
connected to the supply network. The cables should be grounded.
4.2.2. Connection of main power cables

The stator terminals are marked with the letters U, V and W according to IEC 34-8 or T1, T2,
and T3 according to NEMA. Stripping, splicing and insulating of the high-voltage cables must
be performed in accordance with the instructions delivered by the cable manufacturer. The lugs
should not be permanently tightened by busbars, but only attached (for checking of insulation
resistance).
The cables must be supported so that no stress is applied to the busbars in the terminal box, see
the connection diagram in Section 5, Electrical Drawings.
When three-phase cables are used, the prescribed distance must be maintained between the leads
at intersections. Bracing and spacers should be used if necessary.
Mechanical and electrical connections
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Check the phase sequence, see Figure 4-1, Phase sequence (IEC) and Figure 4-2, Phase sequence
(NEMA) .
Figure 4-1 Phase sequence (IEC)

(CW = clockwise, CCW = counter clockwise)
Figure 4-2 Phase sequence (NEMA)

(CW = clockwise, CCW = counter clockwise)
4.2.3. Earthing connection

The connection points for the enclosure earthing can be found in a machine frame, see Figure
4-3, Connection point for earthing cable. In addition, there are points for earthing of main cables
and auxiliary cables in terminal boxes. Purpose of the earthing is to ensure safety and correct
operation of the machine in all conditions. The machine earthing is designed so that the machine
is safe when the earthing connection points are used properly. The locations of the earthing points
can be found in main dimension and terminal box drawings in Section 4, Mechanical Drawings
andSection 5, Electrical Drawings.
Earthing cable connections from the earthing points to must be done in compliance to relevant
requirements of the authorities, including relevant standardization bodies, classifications, local
requirements etc. For correct operation of the machine, VSD drives may have special requirements
for the motor earthing. In many cases, the requirements for proper earthing can be reached by
following the standard IEC 60034-1: Rotating electrical machines – Part 1: Rating and performance.
In Chapter 11.1, the protective earthing is instructed, specifically the minimum cross-section areas
of the earthing conductor. For safety earthing during maintenance and inspection, see also the
instruction of the respective safety equipment provider.
NOTE: Do not remove or modify the internal earthings (equipotential bonding) of

the machine. Modifications may cause sparking or electric charges that can
be dangerous.

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Figure 4-3 Connection point for earthing cable
4.2.4. Insulation distances of main power connections

The connections of the main power cables are designed to withstand demanding operation
conditions where the insulators can be subjected to dirt, humidity and surge voltages. In order to
ensure lasting and trouble-free running, it is therefore important that local requirements or other
applicable standards for the insulation distances are met.
If no local requirements or other applicable standards are available, it is suggested that the minimum
insulation distances mentioned in Table 4-1, Recommended minimum insulation distances are
used.
These distances apply both for insulation distances between two different phases, and for insulation
distances between one phase and the earth. Values for voltages not listed in the table can be
obtained by interpolating.
The air insulation distance is the shortest distance through air between two points with different
electrical potential (voltage). The surface insulation distance is the shortest distance along surfaces
next to each other between two points with different electrical potential (voltage).
Table 4-1. Recommended minimum insulation distances
Main voltage (V) Air insulation dis- Surface insulation distance (mm)
tance (mm) Even surface Finned surface
690 6 10 8
1000 9 14 12
2000 17 27 24
3000 26 41 36
3300 28 45 39
3600 31 49 43
4160 36 57 50
6000 50 80 70

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Main voltage (V) Air insulation dis- Surface insulation distance (mm)
tance (mm) Even surface Finned surface
6600 54 89 77
7200 59 98 85
10000 80 140 120
11500 92 163 140
13800 110 198 170
15000 120 217 186
4.2.5. Connection of auxiliaries and instruments

Connect the instruments and auxiliary equipment according to the connection diagram in Section
5, Electrical Drawings. The locations of auxiliary terminal boxes are shown on drawings in Section
4, Mechanical Drawings.
4.2.6. Automatic Voltage Regulator (AVR)
4.2.6.1. General
AVR (Automatic Voltage Regulator) is a device that continuously monitors the voltage at the
voltage regulating point of the system and automatically initiates corrective actions to maintain
the terminal voltage of the generator. AVR also controls that the synchronous generator operates
within pre-set limits.
A three phase transformer supplies the excitation power to the field winding of the shaft driven
by a three phase exciter under the control of the AVR. A three phase voltage feedback is supplied
by the voltage transformer and a current feedback is provided by the current transformer. The
transformers are installed in the generator.
Operational limits, such as over and under excitation, machine voltage and Volts/Hz, are
implemented in the AVR. Static reactive power compensation in parallel operation and several
other software functions are also available. The AVR is equipped with the PC software for the
AVR.
More detailed information about the AVR used in the specific generator can be found in the
following sections:
• AVR manual, see Section 7, Accessory Information
• system description, see Section 3, Technical Specification
• layout and dimensions, see Section 4, Mechanical Drawings and Section 5, Electrical Drawings.
NOTE: If the AVR is supplied as a loose item without the AVR plate, only the AVR
manual is included.

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4.2.6.2. Configuration
AVR is used as a single-channel system or a dual-channel system. AVR can function either in
automatic or manual mode in both systems.
Single-channel system
The voltage regulator with actual value reading and setpoint formation is active in the automatic
mode. The limiter functions which protect the machine against excessive loads are also active in
the automatic mode. In addition to the actual voltage regulator function, reactive power or power
factor regulators are also available. Reactive power and power factor regulators can be switched
on and off.
NOTE: Reactive power and power factor regulators are not available in island systems.
In the manual mode the actual value is formed from the measurement of the excitation current
and passed with the setpoint value to the excitation current regulator. The output from the regulator
is passed to a switch which is used to select the corresponding mode. This mode is only used for
test purposes and as an emergency regulator in the event of failure of the voltage regulator. The
limiter functions are not active in this mode.
Dual-channel system
The dual-channel system increases the accessibility of the excitation system significantly. The
dual-channel system is equipped with two identical channels. Each channel has the same properties
as a single-channel system. If one channel fails, the system switches to the other channel. Only
one channel (main channel) is in operation at one time. The other channel (redundant channel) is
in standby position and continuously monitors the active channel so that a smooth switchover is
possible at any time.
4.2.6.3. Boosting circuit

In case of short circuit in network or the generator bus bars, the stator voltage drops. Then it is
probable that the AVR loses its excitation power supply and is not able to provide desired amount
of excitation current. It is, however, essential to excite the machine under short circuit to enable
the over current protection to trip the generator. For that reason there is a boosting circuit on the
AVR plate.
The short-circuit current transformers (CTs) mounted inside the generator are wired to the boost
input. The CTs are rated for sustaining a short circuit current of at least 250 % of rated current in
land applications and 300% in marine applications. In normal operation the boosting relay (NC
contacts) short-circuits the secondary of the CTs. If the AVR detects a short circuit (stator voltage
drops below a set level) it energizes the boosting relay. This opens the short circuit of the CTs
and supplies current directly to the excitation field. Diodes are used parallel to the boosting circuit
to ensure a free wheeling for the field current.
The excitation current limiter module is used to adapt the boosting current to a desired level. See
a separate instruction material.
NOTE: Boosting circuit, including the CTs, must be dimensioned properly in order
to avoid harmful over voltages.

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4.2.7. Installation of Automatic Voltage Regulator (AVR)
4.2.7.1. Mechanical installation

For fixing holes and dimensions, see AVR dimensions diagram in Section 5, Electrical Drawings.
The unit should only be installed in indoor areas which are dry and dust-free and do not contain
any gases, acid fumes or similar.
4.2.7.2. Earthing and wiring

The emission limits in accordance with standard EN 50081-2 (1993) 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 are used for the analog and
digital connections.

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Chapter 5 Commissioning
5.1. General
Commissioning is not considered finalized before a commissioning report has been made and
distributed to all concerned parties (customer and supplier).
A commissioning report is a vital tool for future service, maintenance and troubleshooting.
NOTE: The commissioning report has to be sent to ABB in order to obtain future
warranty claims.
A recommended commissioning report can be found in Section 9, Check Lists.
General safety precautions must be followed during commissioning and all work has to be
performed by qualified personnel.
5.2. Check of mechanical installation

Before commissioning:
1. Check the alignment of the machine. Go through the alignment report and ensure that the
machine is accurately aligned according to ABB alignment specifications in Chapter 3,
Installation and alignment.
NOTE: The alignment protocol should always be included in the

commissioning report.
2. Check that the machine is properly anchored to the foundation.
- Check for cracks in the foundation and the general condition of the foundation.
- Check the tightness of the fixing bolts.
3. Open the machine, and check that the air-gap is free. See Figure 3-4, Air-gap between stator
and rotor and Chapter 3.3.3, Air gap check.
4. Before turning the rotor, check that the lubrication system is commissioned and running.
5. If possible, turn the rotor by hand and make sure that the rotor turns freely and that there are
no abnormal sounds.
6. Check the assembly of the main terminal box and cooling system.
7. Check the connection of the oil and cooling water pipes. If applicable, check for leaks when
running.
8. Check the pressure and flow for oil and cooling water, if applicable.
9. Check that all transport locking devices are removed.
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5.3. Check of electrical installation

The power cables can be permanently connected to the terminals in the main terminal box after
the stator insulation resistance has been measured, see Chapter 7.6, Maintenance of stator and
rotor winding.
Before commissioning, check the connection of the power cables:
1. Check that the fixing bolts are tightened to the correct torque.
2. Check that the power cables are suitably routed and do not cause any additional strain on
the terminal bars.
3. Check that the power cables are correctly stress-relieved.
4. Check the connections of the auxiliary equipment.
5. Check the tightness of the cable glands and enclosure sealing.
6. If the cable glands were delivered separately, check that the fixing bolts are tightened with
the correct torque.
5.4. Insulation resistance measurements

Measure the insulation resistances of windings and all auxiliary equipment before making any
electrical connections and applying voltage to the machine.
Measure the insulation of at least the following parts:
• stator and rotor winding
• exciter winding
• bearing insulation (if both bearings are insulated)
• Pt-100 detectors for bearings and air
• anticondensation heaters.
The measured values indicate the condition of the insulation between the winding (or other circuit
to be tested) and the frame of the machine. For detailed information on how to conduct these
measurements see Chapter 7, Maintenance.
If the insulation resistance is under the specified value, it must be corrected before starting the
machine. See Chapter 7, Maintenance for corrective actions.
Measure the insulation resistance well before the first start to leave time for any necessary corrective
actions.
The winding must be dry during the test. The anticondensation heaters should therefore be active
during storage and installation.
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5.5. Automatic Voltage Regulator (AVR)
Pre-settings and testing by ABB

The AVR has been tested with the specific generator and all the basic settings have been modified
and saved so that the AVR will also work at site. The correct AVR and the correct generator can
be identified by checking the serial numbers on the test report. See Section 8, Test Reports.
Settings used in testing can be found in Section 8, Test Reports.
Checking at site before first run

All the settings has to be checked once more at the site of the generator. If there is need to change
the settings it must be done by a qualified person such as an ABB or AVR representative.
NOTE: Settings for the network must also be checked and verified.
NOTE: For detailed information about the settings and commissioning see Section 8,
Test Reports and the system description in Section 3, Technical Specification.
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Chapter 6 Operation
6.1. General
To ensure trouble-free running, a machine must be looked after and carefully supervised.
Always before starting up the machine ensure that:
• the bearings are greased with oil to a correct level in accordance with the manufacturer's
technical specifications and the dimensional drawing
• the cooling system is functioning
• the machine enclosure has been purged and is pressurized if applicable
• no maintenance is ongoing
• personnel and equipment associated with the machine are ready to start up the machine.
For the start-up procedure see Chapter 6.4.1, Starting.

In case any deviations from expected normal operation are noticed, for example elevated
temperatures, noise or vibration, shut down the machine and find the reason for the deviations.
If necessary, consult the manufacturer of the machine.
NOTE: The machine may have hot surfaces when running with load.
NOTE: Overloading the machine may cause demagnetization of the permanent

magnets as well as winding damages.
6.2. Normal operating conditions

The machines manufactured by ABB are individually designed to operate in normal operating
conditions according to the IEC or NEMA standards, customer specifications and internal ABB
standards.
The operation conditions, such as maximum ambient temperature and maximum operating height,
are specified in the performance data sheet. The foundation should be free from external vibration,
and the surrounding air free of dust, salt and corrosive gases or substances.
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6.3. Protection of synchronous generators

Recommended protection of synchronous generators:
• Thermal overload in stator winding; I >
• Network short-circuit, I >>
• Stator interwinding short-circuit, differential protection relay
• Stator earth-fault, earth-fault relay
• Over voltage, Over voltage, relay
• Unbalanced load or shorted turns in the same phase, I2/In
• Under excitation and loss of synchromism, under-reactance relay
• Undervoltage and intermittent loss of voltage, undervoltage relay
• Temperature supervision of temperature detectors, PT-100 monitoring
• Inlet cooling air temperature high
• Leakage water detection (if applicable)
• Lubrication of jack-up pumps not in operation (if applicable)
Additional protection:
• Frequency disturbance
• Reverse power
• Diode fault
• Vibration level
6.4. Start-up procedure

• The hydrostatic jacking system for the bearings is switched on. Switch off hydrostatic jacking
when the machine has reached full speed.
For start-up procedure, see Chapter 6.4.1, Starting.
6.4.1. Starting
Start-up of the machine

The starting of the machine depends on the application, but main guidelines are:
1. Switch the anticondensation heaters off if not operated by switchgear.
2. Start to rotate the machine.
3. Maintain rated speed.
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4. Switch the machine excitation on.
5. Maintain rated voltage.
6. Check sychronizing parameters.
7. Synchronize the machine to the grid.
Recommended values for sychronizing are:
• ΔU = 2 %
• Δf = 0.7 %
• phase angle less than 15°
Maximum values ΔU = 4.5 %, Δf = 4.0 % should not be exceeded.
NOTE: Operation of the machine at reduced speed under 75% of rated speed should
be avoided.
6.4.2. Start interlocking

If the lubricating or cooling systems are provided with pressure or flow monitors, these should
also be included in the start interlocking.
A counter for the number of starts and a duty time meter should be included in the system.
6.5. Continuous supervision

The operating personnel should inspect the synchronous machine at regular intervals. This means
that they should listen to, touch and smell the synchronous machine and its associated equipment
in order to obtain a feeling for normal operating conditions.
The object of the supervision inspection is to thoroughly familiarize personnel with the equipment.
This is essential in order to detect and fix abnormal occurrences in time.
It is therefore recommended that a supervision inspection sheet is filled in. Data from the
supervision inspection should be kept for future reference and can be of help in maintenance work,
troubleshooting and repairs.
The difference between supervision and maintenance is rather vague. Normal supervision of
operation includes logging of operating data such as load, temperatures etc., and the comments
are used as a basis for maintenance and service.
• During the first period of operation (- 200 hours) supervision should be intensive. Bearing
and winding temperatures, load, current, cooling, lubrication, and vibration should be checked
frequently.
• During the following duty period (200 - 1000 hours) a check-up once a day is sufficient. A
record of supervision inspection should be used and filed. If operation is continuous and stable,
the time between inspections may be further extended.
6.6. Shut down procedures

When the synchronous machine is not in operation, anticondensation heaters must be switched
on to avoid condensation inside the machine.
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The hydrostatic jacking system for the bearings is to be switched on for duration of shut down.
Switch off hydrostatic jacking when the machine has reached stand-still.
6.6.1. Shut down

The shut-down of the machine depends on the application, but main guidelines are:
1. Reduce the output of the machine to zero.
2. Open the main breaker.
3. Switch the machine excitation off.
4. Stop the engine.
5. Switch the anticondensation heaters on if not automatically done by switchgear.
6. On water cooled machines, switch off the cooling water flow to avoid condensation inside
the generator.
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Chapter 7 Maintenance
7.1. Preventive maintenance

A synchronous machine often forms an important part of a larger installation. Continuous
supervision and maintaining the machine properly will maximise its reliability in operation.
The purpose of maintenance is therefore:
• To ensure that the machine will function reliably without any unforeseen actions or
interventions.
• To estimate and plan service actions in order to minimize down time.
The difference between supervision and maintenance is rather vague. Normal supervision of
operation and maintenance includes logging of operating data such as load, temperatures, vibrations,
as well as verification of the lubrication, and measurement of the insulation resistances.
After commissioning or maintenance, supervision must be intensive. The temperature of bearings
and windings, load, current, cooling, lubrication and vibration must be checked frequently.
This chapter presents recommendations regarding the maintenance program and work instructions
how to conduct common maintenance tasks. These instructions and recommendations must be
read carefully and be used as a basis when planning the maintenance program. Note that the
maintenance recommendations presented in this chapter represent a minimum level of maintenance.
By intensifying maintenance and supervision activities, the reliability of the machine and the
long-term availability will increase.
The data obtained during supervision and maintenance is useful for estimating and planning
additional service. If some of this data indicates something out of the ordinary, the troubleshooting
guides in Chapter 8, Troubleshooting, will aid in locating the reason for the trouble. ABB states
that experts must be used in the creating maintenance programs, as well as in performing the
actual maintenance and possible troubleshooting.
NOTE: To maintain warranty coverage during warranty period you must follow the
maintenance program.
The ABB Global Service Center organization is happy to assist in these issues. The ABB Global
Service Center contact information can be found in Chapter 9.1.5, Global Technical Support
Center Finland contact information.
An essential part of the preventative maintenance is to have a selection of suitable spare parts
available. The best way to have access to critical spare parts is to keep them in stock. Ready-made
spare part packages can be obtained from the ABB Global Service Center, see Chapter 9.2, Spare
parts.
7.2. Safety precautions

Before working on any electrical equipment, general electrical safety precautions must be taken
into account, and local regulations must be respected in order to prevent personnel injury. This
must be made according to instructions issued by the security personnel.
Personnel performing maintenance on electrical equipment and installations must be highly
qualified. The personnel must be trained in, and familiar with, the specific maintenance procedures
and tests required for rotating electrical machines.
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For general safety instructions, see Section 1, Introduction.
7.3. Maintenance program

This chapter presents the required maintenance program for ABB machines. This maintenance
program is of a general nature, and must be considered as a minimum level of maintenance.
Maintenance should be enhanced when local conditions are demanding or high reliability and
availability are required. Even when following this maintenance program, normal supervision
and observation of the machine's condition is required. Standard maintenance program can be
enhanced and optimised by utilising non-invasive monitoring processes and minimally invasive
advanced inspections. Please contact ABB Motors & Generators service for further information
regarding AbilityTM Predictive Maintenance program.
Please note that although the maintenance program descriptions in this chapter have been
customized to match the machine type, they may contain references to accessories in this particular
machine.
The maintenance program is based on four levels of maintenance, which rotate. The amount of
work and down time increase when we move to longer interval maintenance. Level 1 mainly
includes visual inspections and level 4 more demanding measurements and replacements. More
information about the spare part packages suitable for each type of maintenance can be found in
Chapter 9.2, Spare parts. The required maintenance interval can be seen in Table 7-1,
Recommended maintenance program.
The maintenance intervals in this chapter are given in equivalent operating hours (Eq. h). The
purpose of the term “equivalent” is to highlight that if the operation profile is demanding, the
actual service hour intervals can be adjusted to take this operating profile roughly into account.
Adjustment to the service interval should be considered after the first L1 maintenance taking into
account the maintenance program of other plant equipment, on the observed wear and tear of the
machine, local conditions as well as the criticality of the machine for production.
Some rules of thumb for the equivalent operating hours calculation:
Equivalent operating hours (Eq. h) = 1.2 * Actual operating hours, in case slow-turning is used
or generator is started frequently while generator is not fitted with jack-up units. Consider factor
1.2 also in case of Prime duty. Otherwise use factor 1.
NOTE: Some service activities fall as part of post-commissioning. In particular,

filtering units need to be replaced after first 500 running hours.
Level 1 (L1)
Level 1 or L1 maintenance consists of visual inspections and light maintenance. The purpose of
this maintenance is to perform a quick check in whether problems are beginning to develop, before
they cause failures and unscheduled maintenance breaks. It also gives instructions on what
maintenance issues must be performed in the next, larger overhaul.
This maintenance can be estimated to last approximately 4 - 8 hours, depending on the type and
installation of the machine and the depth of the inspections. Tools for this maintenance include
normal servicing tools i.e. wrenches and screw drives. The preparations consist of opening the
inspection covers. At least the safety package spare parts must be available when commencing
this maintenance.
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First Level 1 maintenance must be performed after 4 000 equivalent operating hours or six months
after commissioning. Subsequently the L1 maintenance must be performed yearly, halfway between
Level 2 maintenance, after max every 10 000 equivalent hours of operations. Details schedule of
L1 should be determined after first L1 (4 000 h) based on rate of wear and contamination on
bearing oil, air filters and lubrication filters. See Table 7-1, Recommended maintenance program.
Level 2 (L2)
Level 2 or L2 maintenance consists mainly of inspections, tests and small maintenance tasks. The
purpose of this maintenance is to find out whether there are problems in the operation of the
machine and to perform small repairs to ensure uninterrupted operation.
This maintenance can be estimated to last approximately 8 - 16 hours, depending on the type and
installation of the machine and the amount of servicing to be done. Tools for this maintenance
include normal servicing tools, a multi meter, a torque wrench and an insulation resistance tester.
Preparations consist of opening the inspection covers and bearings if necessary. Spare parts suitable
for this level of maintenance are included in the maintenance package.
First Level 2 maintenance must be performed after 20 000 equivalent operating hours or two years
after commissioning. Subsequently, L2 maintenance must be performed every two years or after
every 20 000 equivalent operating hours, see Table 7-1, Recommended maintenance program.
Level 3 (L3)
Level 3 or L3 maintenance consists of performing extensive inspections, tests and larger
maintenance tasks that have come up during L1 and L2 maintenance. The purpose of this
maintenance is to solve any problems and replace parts subjected to wear.
This maintenance can be estimated to last approximately 16 - 40 hours, depending on the type
and installation of the machine and the amount of repairs and replacements to be done. Tools for
this maintenance include the same tools as for L2 as well as an endoscope and an oscilloscope.
For water cooled machines cooler cleaning set is recommended and for high voltage machines
(6kV and above) a PD mark repair kit. Pt-100 retrofit kit is recommended to be
available.Preparations consist of opening the inspection covers, the bearings and the water cooler,
if applicable. Spare parts suitable for this level of maintenance are included in the maintenance
package.
Level 3 maintenance must be performed after every 40 000 equivalent operating hours or at a
three to five year interval. When L3 maintenance is conducted it replaces the L1 or L2 maintenance
otherwise scheduled, and it leaves their rotation unaffected, see Table 7-1, Recommended
maintenance program.
Level 4 (L4)
Level 4 or L4 maintenance consists of performing extensive inspections and maintenance tasks.
The purpose of this maintenance is to restore the machine to reliable operating condition.
This maintenance can be estimated to last approximately 40 - 80 hours, mainly depending on the
condition of the machine and the required reconditioning actions. Tools for this maintenance
include the same tools as for L3, as well as the rotor removal equipment. Preparations consist of
opening the inspection covers, bearings and water cooler and the removal of the rotor and exciter,
if applicable.
The number of spare parts required for this level of maintenance is difficult to determine. While
the maintenance package is the minimum requirement, spare parts included in the capital spare
part package would ensure the fast and successful execution of this maintenance.
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Level 4 maintenance must be performed after every 80 000 equivalent operating hour. When L4
maintenance is conducted, it replaces the L1, L2 or L3 maintenance otherwise scheduled, and it
leaves their rotation unaffected, see Table 7-1, Recommended maintenance program.
Table 7-1. Recommended maintenance program
This is an example of maintenance schedule. Detail program should be determined after

4 000 hours of running based on rate of contamination.
Interval [ap-
1 2 3 4 5 6 7 8 9 …
prox. years]
Interval [hours
10 20 30 40 50 60 70 80 90 …
x 1000]
Level L1 L2 L1 L3 L1 L2 L1 L4 L1 …
7.3.1. Mandatory maintenance program

Abbreviations used in maintenance program:
• V = Visual checking
• C = Cleaning and visual checking
• D = Disassembling and assembling, checking, cleaning
• R = Reconditioning or replacement, depending on component
• T = Testing and measurement
NOTE: Not all options are applicable to all machines. Check may indicate need for
replacement, therefore it is recommended to have full recommended spare
parts available.
MAINTENANCE INTERVAL
In equivalent operating hours or time period, whichever comes first
L1 L2 L3 L4
10000 Eq. h 20000 Eq. h 40000 Eq.h 80000 Eq. h
Maintenance object 1 year 2 years 3 - 5 years 10 - 12 years Check / Test
7.3.1.1. General construction

Maintenance object L1 L2 L3 L4 Check / Test
Machine operation V/T V/T V/T V/T Starting, shut down, vibra-
tion measurement, no-load
point, trend values of tem-
peratures
Mounting and founda- V V/T V/T V/T Cracks, rust, alignment,
tion looseness
Exterior V V V V Rust, leakage, condition
Fastenings V V/T V/T V/T Tightness of all fastenings
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Anchor bolts V V V/T V/T Fastening, condition
7.3.1.2. High voltage connection

High voltage cabling V V/T V/T V/T/R Wear, fastening
High voltage connec- V V/T V/T V/T/R Oxidation, fastening, crimp
tions & bolted
Terminal box accessor- V V V V General condition, tightness
ies, i.e. surge capacitors
and arresters
Cable transits V V V C Condition of cables enter-
ing the machine and inside
the machine
7.3.1.3. Stator and rotor

Stator core V V V C Fixing, cracks, welds
Stator winding insulation V V/T V/T/C T/C Wear, cleanliness, insula-
tion resistance, polarization
index and stator diagnostics
measurements1
Stator coil overhangs V V V V Insulation damage
Stator coil supports V V V V Insulation damage
Stator slot wedges V V V V Movement, tightness
Stator terminal bars V V V V Fixing, insulation
Stator cable terminal V V/T V/T V/T Tightness, condition
fastenings and crimps
Instrumentation V V V V Condition of cables and
cable ties
Rotor poles V V/T V/T V/T Movement, tightness, fix-
ing2
Rotor winding insulation V V/T T/C T/C Wear, cleanliness, insula-
tion resistance, voltage drop
test
Rotor coil supports V V V V Movement, bending
Rotor balancing weights V V V V Movement
Damper bars, damper V V/T V/T V/T Cracks, corrosion, ultra
joints, fans sound and knocking test
Shaft and rotor center V V V V Cracks, corrosion
Air gap V V/T V/T V/T/D Equality
Connections in rotor V V V/T V/T Fixing, general condition
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Earthing brushes V V V V/R Operation and general con-
dition
Rotor shaft insulation V V V/T V/T General condition, insula-
tion resistance
1) Stator diagnostics measurements are optional but recommended to evaluate accurately proactive maintenance needs.
ABB LEAP is the recommended method. Other methods include PD measurements.
2) Tightness of possible dovetail connection wedges to be tested
7.3.1.4. Excitation system, control and protection

Exciter diode bridge V T/C T/C T/C Cleanliness, operation
Exciter semiconductors, V T/C T/C R Operation, fixing
diodes, varistors
Excitation connections V T/C T/C T/C Fixing, general condition
Exciter winding insula- V V/T V/T V/T Wear, cleanliness, insula-
tion tion resistance
Exciter air gap V V/T V/T V/T/D Equality
AVR unit V V/T V/T V/R Operation, settings, stability
test
AVR board V V/T V/T V/R Operation, connections
PMG V V V/T V/T Operation, connections
Voltage transformer V V/T V/T V/T Operation, cleanliness
(VT)
Short circuit current V V V/T V/T Operation, cleanliness
transformer (CT)
Actual value CT V V V/T V/T Operation, cleanliness
Measurement and protec- V V V/T V/T Operation, cleanliness
tion CTs
Pt-100 elements (stator, V V/T V/T V/T Resistance, insulation resist-
cooling air, bearing) ance
Anticondensation heaters V V/T V/T R Operation, insulation resist-
ance
Auxiliary terminal boxes V V/T V/T V/T General condition, termin-
als, wiring condition
Exciter stator fixing V V V V General condition, cracks
7.3.1.5. Lubrication system and bearings

Bearing assembly V V/T V/T V/T/D Fixing, general condition
Bearing shells V V V/T/D R General condition, wear
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Seals and gaskets V V V/T/D R Leakage
Bearing insulation V V/T V/T/D V/T/D Condition, insulation resist-
ance
Lubrication piping V V V/T/D/R V/T/D Leakage, operation. Re-
place high pressure parts.
Lubrication oil V/R V/R V/R V/R Quality, quantity, flow
Oil ring V V V R Operation
Oil flow regulator V V/T V/T V/T/D Operation
Oil tank V C C C Cleanliness, leakage
Lubrication unit or jack- V V/T V/T R Operation, replacement of
up system pump, motor or coupling
Oil cooler / heater T T T T Oil temperature
Filters R R R R Lubrication & jack-up unit
See also separate instruction for lubrication units.
7.3.1.6. Cooling system

Fan(s) V V V V Operation, condition
Filters C R R R Cleanliness, operation
Air ways V C C C Cleanliness, operation
Top module housing V V V R
gaskets

Heat exchanger V V D D Leakage, operation, pres-
sure test
Fan, incl. motor V/T V/T V/T V/T Operation, condition, fan
power measurement
Tubes * V V C C Cleanliness, corrosion
Ducts V V C C Cleanliness, operation
End chambers V C D D Leakage, condition
End chamber seals and V C R R Leakage, condition
gaskets
Top module housing V V V R
gaskets
Plate fins V V C C General condition
Vibration dampers V V R R Condition and profile
Protective anodes C C Condition, activity
Water flow regulator V/T V/T V/T V/T Operation
Leakage detector V/T V/T V/T R
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* For tube cleaning, a tube brush set is required.
7.4. Maintenance of general construction

To ensure a long life span for the general construction of the machine, the machine exterior must
be kept clean and be periodically inspected for rust, leaks and other defects. Dirt on the machine
exterior exposes the frame to corrosion and may affect the cooling of the machine.
7.4.1. The tightness of fastenings

The tightness of all fastenings must be verified regularly. Special attention must be paid to the
electrical connections, anchor bolts and the rotor parts, which must remain correctly tightened at
all times. Loose fastening in these parts may lead to sudden and severe damage to the entire
machine.
General values for tightening torques are presented in Tables 7-2, General tightening torques 1,
7-3, General tightening torques 2 and 7-4, General tightening torques 3. There is a separate table
also for insulation supports. This chapter is applicable to all general type of screws in the machine.
In particular these tables are not applicable to tightening of pole fixing bolts, foundation anchor
bolts or electrical components like diodes or transformers. These are tightened according to
separate instruction in the accessory section of the manual.
M10 bolts with sealing washers are used for fastening the covers. For these use only 35 Nm (dry)
torque to ensure fastening without breaking the washer.
The tightening torques and corresponding tightening forces for screws of property class 8.8., 10.9
and 12.9
Note! Bolt head is not oiled or greased.
The thread should be lightly oiled to get friction coefficient μ=0.1 or MoS2 greased to get friction
coefficient μ=0.08. If oiling or greasing is not possible. μ=0.16 is used as a friction coefficient.
The recommended type of oil: Wurth, HHS 2000.
The recommended type of MoS2 grease: Rocol, Dry Moly Paste.
Table 7-2. General tightening torques 1
Property
Tightening torque Nm Tightening force kN
class 8.8
MoS2 MoS2
Screw dry oiled dry oiled
greased greased
M4 3.0 2.8 2.7 3.3 3.5 3.7
M5 5.5 5.4 5.2 4.9 5.8 6.0
M6 9.5 9.3 9.1 7.1 8.1 8.4
M8 24 22 22 13 15 15
M10 46 45 44 21 23 25
M12 80 76 75 31 34 36
M14 130 120 120 43 47 49
M16 200 180 180 59 64 68
M 20 390 360 350 91 100 110
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Property
class 8.8
MoS2 MoS2
greased greased
M 24 660 620 600 130 150 150
M 27 980 920 900 170 190 200
M 30 1300 1200 1200 210 220 240
M 36 2300 2200 2100 300 350 350
M 39 3000 2800 2700 370 410 420
M 42 3600 3500 3400 410 470 490
M 48 5600 5300 5100 560 630 640
M 56 9000 8500 8200 770 870 890
M 64 14000 13000 12000 1000 1200 1200
M 72 x 6 20000 18000 18000 1300 1500 1600
M 80 x 6 27000 25000 24000 1700 1900 1900
M 90 x 6 40000 36000 35000 2200 2400 2500
M 100 x 6 55000 50000 48000 2700 3000 3100
Property
class 10.9
MoS2 MoS2
greased greased
M4 4 3.8 3.8 4.4 4.9 5.1
M5 7.9 7.6 7.4 7.3 8.1 8.4
M6 14 13 13 10 11 12
M8 22 32 31 19 21 21
M10 65 63 62 29 33 34
M12 110 110 110 42 50 53
M14 180 170 170 59 66 71
M16 270 260 250 81 92 94
M 20 540 510 500 130 143 150
M 24 930 880 850 180 210 210
M 27 1400 1300 1300 250 270 290
M 30 1900 1800 1700 300 340 340
M 36 3300 3100 3000 440 490 500
M 39 4200 4000 3900 520 580 610
M 42 5200 4900 4800 590 660 690
M 48 7900 7400 7200 780 870 910
M 56 13000 12000 12000 1100 1200 1300
M 64 19000 18000 17000 1400 1600 1600
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Property
class 10.9
MoS2 MoS2
greased greased
M 72 x 6 27000 26000 25000 1800 2100 2200
M 80 x 6 38000 35000 34000 2400 2600 2700
M 90 x 6 55000 51000 49000 3000 3400 3500
M 100 x 6 76000 71000 68000 3800 4300 4400
Property
class 12.9
MoS2 MoS2
greased greased
M4 4.9 4.8 4.7 5.4 6 6.3
M5 9.5 9.2 9.0 8.7 9.9 10
M6 17 16 16 13 14 15
M8 40 38 38 23 25 27
M10 80 77 76 36 40 43
M12 140 130 130 54 59 62
M14 220 210 200 73 81 83
M16 340 320 310 100 110 120
M 20 660 620 610 160 170 180
M 24 1100 1100 1100 220 260 280
M 27 1700 1600 1500 300 330 340
M 30 2300 2100 2100 360 390 420
M 36 4000 3700 3600 530 580 610
M 39 5200 4800 4700 640 700 730
M 42 6400 6000 5900 730 810 850
M 48 9600 9100 8800 950 1100 1100
M 56 16000 15000 14000 1400 1500 1500
M 64 23000 22000 21000 1700 2000 2000
M 72 x 6 33000 31000 30000 2300 2500 2600
M 80 x 6 46000 43000 42000 2900 3200 3400
M 90 x 6 67000 62000 60000 3700 4100 4300
M 100 x 6 94000 87000 83000 4700 5200 5400
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NOTE: The values in Tables 7-2, General tightening torques 1, 7-3, General tightening
torques 2 and 7-4, General tightening torques 3 are general, and do not apply
to various items, such as diodes, support insulators, bearings, cable terminals
or pole fastenings, surge arrester, capacitors, current transformers, rectifier
and thyristor bridges, or if some other value is given elsewhere in this manual
or in the mechanical and electrical drawings, see Section 4, Mechanical
Drawings and Section 5, Electrical Drawings.
The tightening torques and corresponding tightening forces for acid-proof stainless steel (austenitic)
screws
The thread of screws waxed or lubricated with thread locking compound (μ=0.16).
Table 7-5.
Screw Tightening torque Nm Tightening force kN

Property class A4 - 80 A4 - 80
M4 2.7 2.9
M5 5.4 4.8
M6 9 6.7
M8 22 12
M10 44 20
M12 75 29
M14 120 40
M16 190 56
M20 370 87
M22 490 105
M24 630 124
Property class A4 - 50 A4 - 50
M27 320 56
M30 440 69
M33 590 85
M36 760 100
M39 980 120
Table 7-6. Tightening torques for the support insulators and 2CT/3CT current transformers
Size Torque Nm
M4 1.0
M5 2.5
M6 3.3
M8 8.0 ± 1
M10 16.0 ± 2
M12 28.0 ± 3
M16 68.0 ± 8
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Size Torque Nm
M20 135.0 ± 15
M24 225.0 ± 25
7.4.2. Vibration and noise

High or increasing vibration levels indicate changes in the machine's condition. Normal levels
vary greatly depending on the application, type and foundation of the machine. The vibration
measurements and levels are discussed in detail in Chapter 5, Commissioning. Some typical
reasons that might cause high noise or vibration levels are:
• Alignment, see Chapter 3, Installation and alignment
• Air gap, see Chapter 3, Installation and alignment
• Bearing wear or damage, see Section 7, Accessory Information
• Vibration from connected machinery, see Chapter 5, Commissioning
• Loose fastenings or anchor bolts, see Chapter 3, Installation and alignment
• Rotor imbalance
• Coupling
7.4.3. Rotor construction control

Particular attention must be paid to rotor construction, because even minor damage in the rotor
can lead to severe damage in the stator. In addition, mechanical problems in the moving parts
such as the rotor, have a tendency to develop faster than in the stationary parts of the machine.
Therefore, rotor construction must be checked yearly, preferably using an endoscope and ultrasonic
equipment. The condition and tightness of the fastenings must be checked carefully.
7.4.4. Checks during running of the machine

During the first days of running, it is important to keep the machine under close surveillance in
case any changes occur in the vibration or temperature levels, or there are abnormal sounds.
7.4.4.1. Normal vibration levels

The following instructions are part of the following two ISO standards:
1. ISO 10816-3:1998 Mechanical vibration - Evaluation of machine vibration by measurements

on non-rotating parts: Part 3: Industrial machines with nominal power above 15 kW and
nominal speeds between 120 r/min and 15 000 r/min when measured in situ.
2. ISO 8528-9:1995 Reciprocating internal combustion engine driven alternating current

generating sets: Part 9: Measurement and evaluation of mechanical vibrations.
7.4.4.1.1. Measurement procedures and operational conditions

General procedures described in ISO 10816-1 are used, subject to the requirements listed below.
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Measurements are usually made when the rotor and the main bearings have reached their normal
steady-state operating temperatures and the machine is running under specified conditions, for
example at rated speed, voltage, flow, pressure and load.
On machines with varying speeds or loads, measurements must be made under all conditions in
which the machine is expected to operate for prolonged periods. The maximum measured value
under these conditions is considered representative of vibration severity.
If the measured vibration exceeds the acceptance criteria and excessive background vibration is
suspected, measurements must be made with the machine shut down to determine the degree of
external influence. If the vibration with the machine stationary exceeds 25 % of the value measured
when the machine is running, corrective actions may be necessary to reduce the effect of
background vibration.
Measurement equipment
The measurement equipment must be capable of measuring broad-band r.m.s vibration with a flat
response over a frequency range of at least 10 Hz to 1000 Hz, in accordance with ISO 2954.
Depending on the vibration criteria, this may require measurements of displacement or velocity
or combinations of these (see ISO 10816-1). However, for machines with speeds approaching or
below 600 r/min, the lower limit of the flat response frequency range must not be greater than 2
Hz.
Measurement locations
Use a measurement location that is exposed and accessible during normal operation. Make sure
that there are no local resonances or amplification so that the final measurements will reasonably
represent the vibration of the bearing housing. The locations and directions of vibration
measurements must have adequate sensitivity to the machine´s dynamic forces. Typically, this
will require two orthogonal radial measurement locations on each bearing cap or pedestal, as
shown in Figure 7-1, Measuring points. Place the transducers at any angular position on the
bearing housings or pedestals. Vertical and horizontal directions are usually preferred for
horizontally mounted machines. For vertical or inclined machines, the location that gives the
maximum vibration reading, usually in the direction of the elastic axis, is usually used. In some
cases, the vibration must also be measured in the axial direction. When recording the results of
the measurements, record the specific locations and directions with the actual values.
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Figure 7-1 Measuring points
7.4.4.1.2. Evaluation of RIC engine generating sets

The main excitation frequencies of the RIC engine (Reciprocating Internal Combustion) are in
the range of 2 Hz to 300 Hz. However, when considering the overall generating set structure and
components, a range of 2 Hz to 1000 Hz is required to evaluate the vibration.
ISO 8528-9 is used as guideline evaluate vibration severity of AMG generators. ISO 8528-9
provides a vibration severity assessment table C.1 with two different criteria value levels: Value
1 and Value 2. The simplified version of the table is shown below.
According to the standard no damage would be expected if vibration levels remain below value
1. Further on, if the vibration levels fall between values 1 and 2, assessment of the generating set
structure and components may be required, along with an agreement between the generating set
manufacturer and the component supplier in order to ensure reliable operation.
For AMG generators the assessment has been already done for standard engine combinations. In
this assessment the value 1 vibration levels (e.g. 15 mm/s for speeds 720 rpm and below) is the
target value for engine design, but installed values up to Value 2 (e.g. 20 mm/s for speeds 720
rpm and below) have been considered in design and are acceptable.
In some cases vibration levels can be even above value 2, but only if individual special designs
of generating set structure and components are applied. Note that vibration level limits apply only
for the measurement points defined in standard. For example in sheet metal parts there are points
where Value 1 or Value 2 limits are exceeded.
In all cases, the generating set manufacturer remains responsible for the compatibility of the
generating set components (see ISO 8528-5:1993, 15.10).
Table 7-7. Vibration velocity, Vrms
Declared engine speed [rpm] Value 1 [mm/s] Value 2 [mm/s]

≥1300 but <2000 20 28
>720 but <1300 18 22
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Declared engine speed [rpm] Value 1 [mm/s] Value 2 [mm/s]

≤720 15 20
Additional information
For more details about vibration measuring, see the following International Standards where
applicable:
• ISO 2954 Mechanical vibration of rotating and reciprocating machinery - Requirements for
instruments for measuring vibration severity
• ISO 5348 Mechanical vibration and shock - Mechanical mounting of accelerometers
• ISO 7919 Mechanical vibration of non-reciprocating machines - Measurements on rotating

shafts and evaluation criteria
• ISO 8528 Reciprocating internal combustion engine driven alternating current generating sets
• ISO 10816 Mechanical vibration - Evaluation of machine vibration by measurements on

non-rotating parts
7.4.4.2. Temperature levels

The temperatures of the bearings, stator windings and cooling air must be checked when the
synchronous machine is running.
The bearings may not reach a stable temperature until after several (2 - 6) hours, when running
at full speed.
The stator winding temperature depends on the load of the machine. If full load cannot be reached
during or soon after commissioning, the present load and temperature must be noted and included
in the commissioning report.
For the default values for ALARM and TRIP levels, see the main connection diagram in Section
5, Electrical Drawings.
The temperature alarm levels for resistance temperature detectors (RTD, Pt-100) must be set as
low as possible in order to detect any rapid abnormalities and trend changes as early as possible.
A suitable level can be determined based on the test results, or preferably based on the observed
operating temperatures. The temperature alarm must be set 10K (20°F) higher than the operating
temperature of the machine during maximal loading at the highest coolant temperature.
Recommended procedure for alarm value setting based on site conditions:
1. Initially set the alarm value according to the Main Connection Diagram
2. Run the machine for a minimum of 6 hours at the intended operation point
3. Measure the temperature values related to the alarms and the cooling media. (i.e. the cooling
air or the cooling water or cooling oil)
4. Evaluate the maximum temperature variation in the cooling media
5. Consider other possible sources of higher machine temperatures, such as higher load, higher
speed, different power factor etc.
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6. Calculate the alarm value as follows: start with the measured temperature at the operation
point, add in temperature variations in the cooling material as well as those of other possible
sources of higher machine temperatures. In order to obtain the alarm value, add an additional
10 degrees C to the previously calculated value
7. Compare the above alarm value to the maximum value given in the Main Connection Diagram,
and choose the lower value as the alarm set value
NOTE: Do not change the trip limits. If the typical operation point values change,
re-set the alarm values.
NOTE: If an alarm limit appears to be too low, contact ABB for determining most
suitable settings.
Example:
Measured stator Pt-100 value at operation point: 107 degrees C. Potential increase in ambient air
temperature: 7 degrees C. Increase in temperature as a result of lower power factor: 4 degrees C.
The calculated alarm set point is: 107 + 7 + 4 + 10 = 128 degrees C. As this value is lower than
the value in the Main Connection Diagram, it will be used as the alarm set point.
7.5. Maintenance of lubrication system and bearings

This section covers the most important maintenance tasks for the bearings and the lubrication
system. Other relevant information about bearing and lubrication can be found in Section 7,
Accessory Information and Section 4, Mechanical Drawings.
7.5.1. Lubrication
The machines are equipped with sleeve bearings that have a very long service life provided that:
• the lubrication functions continuously
• the oil type and quality are as per ABB recommendations
• the oil change instructions are followed. For detailed instructions, see this sub-section as well
as the manual for bearings in Section 7, Accessory Information. For oil details, see Main
Dimension Drawing in Section 4, Mechanical Drawings.
7.5.1.1. Lubrication oil temperature

The correct lubrication oil temperature is essential to keeping the bearing at the correct operating
temperature and ensuring sufficient lubrication effect and the correct viscosity of the lubrication
oil. For machines equipped with oil supply, the poor operation of oil cooler or heater and incorrect
oil flow can cause oil temperature problems. For all bearings, the correct oil quality and quantity
must be checked if temperature problems appear. For more information see Chapter 7.5.1.2,
Condition of the lubricant and Chapter 7.5.1.3, Oil qualities.
7.5.1.2. Condition of the lubricant

Check the oil with respect to color, smell, turbidity and deposits in a test bottle.
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The following requirements must be fulfilled:
• The oil must be free from debris, and its cleanliness according to ISO 4406 class 19/17/14,
or NAS 1638 class 8.
• The quantity of metal impurities must be less than 100 PPM. Increasing trend of the value
means that the bearing is wearing.
• The oil must be clear or negligibly turbid. The turbidity must not be caused by water.
The water content must not exceed 0,2%
• A strong acid or burnt smell is not acceptable.
The original viscosity must be maintained within a tolerance of ± 15%.

The total acid number ((TAN) allowable change to fresh oil ± 1 mg KOH per gram of oil). Please
note that TAN value is not same as TBN (total base number) value.
An oil check must be performed a few days after the first test run of the machine, just before the
first oil change. And subsequently as required. If the oil is changed shortly after commissioning,
it can be used again after removing wear particles by filtering or centrifuging.
In doubtful cases, an oil sample must be sent to a laboratory to determine viscosity, acid number,
foaming tendency, etc.
7.5.1.3. Oil qualities

The oils listed below are lubricants based on paraffin, which have a high viscosity index value
(VI > 90) and a particularly low fluid temperature. The oils listed below include the following
additives:
• oxidation and rust inhibitor
• anti-foaming agent
• mild EP action, anti-wear additive.
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Unless otherwise stated on ABB drawings, the bearings are designed for any of the oil qualities
described below.
ISO VG 150
Viscosity 150 cSt at 40 °C
Synthetic Oils
No suggestion
Mineral Oils
Aral: Degol CL 150 T

BP: Energol THB 150, Energol CS 150
Castrol: Hyspin VG 150
Chevron: AIO ISO 150, Regal R&O 150
Esso: Teresstic T 150
Exxon: Teresstic 150
Fuchs: Renolin DTA 150
Klüber: CRUCOLAN 150
Mobil: Mobil DTE Oil Extra Heavy
Shell: Morlina Oil 150
Total: Carter EP 150
7.5.1.4. Oil change schedule for mineral oils

For self-lubricated bearings, cleaning intervals with oil changes of approximately 4000 operating
hours are required and approximately 20000 operating hours for bearings with oil circulation
systems.
Shorter oil change intervals may be necessary in the case of frequent start-ups, high oil temperatures
or excessively high contamination due to external influences.
7.5.2. Sleeve bearings

In normal operating conditions, sleeve bearings require little maintenance. To ensure reliable
operation the oil level and the amount of oil leakage must be checked regularly. For more detailed
information on the bearings, see Section 7, Accessory Information.
7.5.2.1. Oil level

The oil level of a self-lubricated sleeve bearing needs to be checked regularly. The nominal oil
level and maximum and minimum oil level limits can be found either from Section 7, Accessory
information or from Section 4, Mechanical Drawings depending on the bearing type. Typically,
the nominal oil level is in the middle of the sight glass, the minimum oil level is at the bottom of
the oil sight glass and the maximum oil level is at the top of the oil sight glass.
If necessary, refill with a suitable lubricant, see Section 4, Mechanical Drawings, Chapter 3.1.1,
General and Chapter 7.5.1.3, Oil qualities.
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The correct oil level of a flood-lubricated sleeve bearing is the same as for a self-lubricated bearing.
In flood-lubricated bearings, the oil sight glass can be exchanged for an oil outlet flange. Dry
sump type bearings have no oil reservoir inside the bearing and an oil sight glass is not therefore
needed.
7.5.2.2. Bearing temperature

The bearing temperatures are measured by Pt-100 resistance temperature detectors. The normal
bearing temperature must be 65 - 85 °C. Since a temperature rise above the alarm limit can be
caused either by increased losses in the bearing, or by decreased cooling capacity, this often
indicates a problem somewhere in the machine or in the lubrication system, and must therefore
be closely monitored. The factory set alarm and trip limits are stated in the Main Connection
Diagram, see Section 5, Electrical Drawings.
The reasons for abnormal bearing temperature vary, but for some possible reasons, see Chapter
7.5.1, Lubrication or Chapter 8, Troubleshooting. If the temperature rise is followed by an increase
in vibration levels, the problem might also be related to the machine's alignment, see Chapter 3,
Installation and alignment or to a damage in the bearing shells, in which case the bearing needs
to be dismantled and checked, see Section 7, Accessory Information.
7.5.3. Oil leakage of sleeve bearings

The construction of a sleeve bearing is such that it is very difficult to avoid oil leakage completely,
and therefore small amounts of leakage must be tolerated.
However, oil leakage can also appear because of reasons other than the bearing design, such as
incorrect oil viscosity, over pressure inside the bearing, under pressure outside the bearing, or
high vibration levels at the bearing.
If excessive oil leakage is noted, please check/verify the following:
• Verify that the oil used is according to specifications
• Re-tighten the bearing housing halves, and the labyrinth seal cover. This is especially important,
if the machine has been stopped for a long time
• Measure the vibrations of the leaking bearing in three directions under full load. If the vibration
level is high, the bearing housing might "loosen" just enough to permit the oil to wash away
the sealant between the housing halves
• Open the bearing, clean the surfaces and apply new sealant between the bearing housing halves
• Verify that there is nothing, which might cause low pressure next to the bearing. A shaft or
coupling cover can for instance be designed so that it will cause low pressure near the bearing
• Verify that there is no over pressure inside the bearing. Over pressure may be entering the
bearing through the oil outlet piping from the oil lubrication unit. Apply breathers or vents to
the bearing housing so as to relieve the over pressure from the bearing
• In the case of a flood bearing lubrication system, check that the slope of the oil outlet pipes
is sufficient.
If excessive oil leakage is found, even after all of the above and below mentioned things have
been checked and verified, please fill in the form Oil Leakage's at RENK Sleeve Bearings and
send it to the ABB Service.
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7.5.3.1. Oil
In order for the bearings to function as expected, the oil has to meet certain criteria like viscosity
and cleanliness.
Viscosity
The bearings are designed to run with an oil of a certain viscosity, which is mentioned in the
documentation provided with the electrical machine. Incorrect viscosity will lead to lubrication
failures, and can damage the bearings, as well as the shaft.
7.5.3.2. Sleeve bearings

The sleeve bearings used in rotating electrical machines are often 'standard bearings' used in a
number of applications. Therefore, the bearing design in itself is normally not the cause of bearing
leakages, and the reason for the leakage must be found elsewhere.
However, the bearing is assembled from several parts, and the joints between the parts can leak
due to faulty assembly or lack of sealing compound.
Bearing housing
The bearing housing consists of an upper and lower half, which are joined together. In addition,
labyrinth seals are mounted on the bearing housing entrance of the shaft. This construction is not
completely hermetic, and therefore very small leakages must be tolerated.
A tolerable amount of leakage for self-lubricating bearings is such that the bearing does not need
a top-up between the oil change intervals.
The oil can leak from the bearing in two ways:
• Past the labyrinth seals
• Through the split line of the bearing housing.
Sealant
In order to prevent the oil from leaking from the bearing through any split lines, sealant is applied
on the split lines. Only Hylomar Blue Heavy sealing compound, Curil T or other similar compounds
may be used for this.
7.5.3.3. Bearing verification

In case the oil leakage is suspected to originate in the bearing housing itself, the following steps
must be taken:
1. Re-tighten the bearing housing

This is especially important during the commissioning of the machine, or if the machine has
been standing still for a longer period, as the parts may set.
If the bearing housing halves are not in a tight fit in respect to each other, the oil might wash
away the sealant from the split line. This in turn will cause oil leakage.
2. Open the bearing housing
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The bearing housing can be opened, and new sealant applied on the split lines. Care has to
be taken that no dirt or foreign matter enter the bearing during this procedure. The split lines
must be completely re-greased before a thin layer of sealant is applied.
7.5.3.4. Oil container and piping

A separate oil container and piping is used only for flood-lubricated bearings.
Oil container
The oil container can be either a separate container, or in some cases, the crankcase of a diesel
engine. In both cases, the container has to be well below the bearings, in order for the oil to flow
to the container from the bearing.
The oil container must be constructed in such a way that no pressure can enter the oil return piping
from the container towards the bearing.
Oil piping
The function of the oil return piping is to allow the oil to return to the oil tank with as little of
friction as possible. This is normally obtained by choosing a piping diameter of a large enough
diameter, so that the flow of the oil in the return line does not exceed 0.15 m/s (6 inch/s) based
on the pipe cross section.
Install the oil outlet pipes downwards from the bearings at a minimum angle of 15°, which
corresponds to a slope of 250 - 300 mm/m (3 – 3½ inch/ft).
The assembly of the piping must be performed in such-a-way that above mentioned slope is present
at all points of the piping.
7.5.3.5. Oil container and piping verification

In case the oil leakage is suspected to originate in the construction of the oil container or the oil
piping, the following steps can be taken:
Pressure in oil container

The atmospheric pressure inside the oil container must be verified. The pressure may be no greater
than the pressure outside the bearing. If this is the case, a breather must be installed to the oil
container.
Oil piping
It must be verified that the piping has a sufficient diameter, is not clogged, and that the slope is
downward and sufficient throughout the oil return piping.
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7.5.3.6. Use
Causes for bearing leakages, apart from being installation-related, some causes are 'use' related.
Oil pressure
The inlet oil pressure for each bearing is calculated according to the desired oil flow, and therefore
the oil pressure must be adjusted accordingly during commissioning. The specific oil pressure
value for each machine must be verified from the documentation provided with the machine.
Oil temperature
The correct lubrication oil temperature is essential in keeping the bearing at the correct operating
temperature, in ensuring sufficient lubrication effect, and correct viscosity of the lubrication oil,
see Chapter 7.5.1.1, Lubrication oil temperature.
Vibrations
All machines are subjected to, and designed to withstand vibrations. Large vibrations might cause
the various parts in the bearing to function differently to the way intended.
Heavy vibrations can cause different phenomena in the oil film between the shaft and the white
metal, but this will rather seldom lead to oil leakages. Instead, vibrations might cause bearing
failures.
Heavy vibrations can cause the bearing housing parts to set, or to 'loosen up' just enough to allow
the oil to enter the split surface between the upper and the lower bearing housing halves. The
vibrations will cause the bearing housing parts to move in respect of each other. This can cause
a 'pumping' effect in such a way, that oil will be pumped in and out from the split surface. This
will eventually remove the sealant, and cause the bearings to leak.
Over pressure inside the bearing

The bearing housing is not a hermetic compartment, and therefore any over pressure inside the
bearing housing will escape the bearing housing via the labyrinth seals. In escaping, the air will
bring oil mist with it, thus causing the bearing to leak.
Over pressure inside the bearing is normally caused by components other than the bearing itself.
The most common reason for over pressure inside the bearing is over pressure in the oil return
piping.
Under pressure inside the bearing

Similar to over pressure inside the bearing, under pressure outside the bearing will 'suck' air out
from inside the bearing, thus bringing oil with it, and causing the bearing to leak oil.
Under pressure inside the bearing is normally not caused by the bearing itself, but by parts outside
the bearing.
Under pressure near the bearing housing is caused by rotational parts moving the air next to them
in such a way that a local under pressure is formed next to the exit of the shaft of the bearing.
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7.5.4. Bearing insulation resistance check

The bearing insulation resistance check is a maintenance operation performed primarily in the
factory during final assembly and testing. It must also be made during all comprehensive overhauls
of the machine. Good insulation is necessary in order to eliminate the possibility of circulating
bearing currents, which might be induced by shaft voltages. The insulation of the non-drive end
bearing cuts the path of the bearing current and thus eliminates the risk of bearing damages due
to bearing currents.
The drive-end shaft of an electrical machine must be earthed, because an unearthed shaft would
have an unknown electrical potential compared to the surroundings and would therefore be a
potential source of damage. However, to make the testing of the non-drive end bearing insulation
easier, the drive end bearing is also often insulated. This insulation is short-circuited by an earthing
cable during normal operation; see Figure 7-2, D-end bearing earthing cable.
NOTE: Machines with insulated bearings have a sticker indicating the insulated
bearing.
NOTE: Variable speed drive (VSD) motors that are fed by a converter, have both a
drive end and non-drive end bearing, insulated with the shaft earthed by
brushes at the drive end.
7.5.4.1. Procedure
For machines with an insulated drive end bearing, the short-circuit earthing cable in the drive end
bearing (or earthing brushes on shaft) must be removed prior to commencing the non-drive end
bearing insulation resistance test. If the drive end bearing is not insulated, the non-drive end
bearing insulation resistance test requires the removal of the drive end bearing, or the removal of
the bearing housing cover, and lifting of the shaft, so that there is no electrical contact between
the shaft and any other part, for example the frame or bearing housing. Therefore, when the drive
end bearing is insulated, the measurement of the non-drive end bearing must only be conducted
by qualified personnel.
Figure 7-2 D-end bearing earthing cable
For all machines, any optional shaft earthing brush, rotor earth fault brush and coupling (if it is
made out of conductive material) must be removed. Measure the insulation resistance from the
shaft to earth according to Chapter 7.6.4, Insulation resistance – measurement and minimum
values.
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Figure 7-3 The testing of bearing insulation resistance
7.5.5. Bearing clearance measurements

The bearing clearance is measured by opening the upper bearing shell, which makes it possible
to measure the clearance with for example a lead wire at the top and at the sides of the shaft. The
measuring at the top of the shaft is carried out by placing 40...50 mm pieces of about 1 mm thick
lead wire on top of the shaft and on the split surfaces at both sides of the lower bearing shell. The
upper bearing shell is then lowered to rest on the wires and pressed lightly. The thickness of the
pressed wires is measured with a micrometer.
The bearing clearance is calculated from the formula:
S = A - [(B1 + B2) ÷ 2]
where S= bearing clearance (mm)

A= thickness of lead wire on top of shaft (mm)
B1 = thickness of lead wire on split surface (mm)
B2 = thickness of lead wire on split surface (mm)
The clearance values are given on the dimension drawing or they can be roughly estimated from
the formula:
S = (n × D)¼ × (D ÷ 14500)
where S = bearing clearance (mm)

D = shaft diameter at the bearing (mm)
n = rotating speed (r/min)
7.6. Maintenance of stator and rotor winding

The windings of rotating electrical machines are subjected to electrical, mechanical and thermal
stress. The windings and insulation gradually age and deteriorate due to the stress. Therefore, the
service life of the machine often depends on the insulation durability.
Many processes leading to damages can be prevented or at least slowed down with appropriate
maintenance and regular testing. This chapter offers a general description on how to perform basic
maintenance and tests.
In many countries, the ABB Service also offers complete service maintenance packages, which
include comprehensive testing.
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Before conducting any maintenance work on the electrical windings, general electrical safety
precautions must be taken and local regulations are to be respected in order to prevent personnel
accidents. See Chapter 7.2, Safety precautions for more information.
Independent test and maintenance instructions can also be found in the following international
standards:
1. IEEE Std. 43-2000, IEEE Recommended Practice for Testing Insulation Resistance of
Rotating Machines
2. IEEE Std. 432-1992, IEEE Guide for Insulation Maintenance for Rotating Electrical
Machinery (5 hp to Less Than 10 000 hp)
7.6.1. Particular safety instructions for winding maintenance

Some of the hazardous works of the winding maintenance include:
• Handling of hazardous solvents, varnishes, and resins. Hazardous substances are required for
cleaning and re-varnishing windings. These substances can be dangerous if inhaled, swallowed
or in any contact with skin or other organs. Seek proper medical care if an accident occurs.
• Dealing with flammable solvents and varnishes. Handling and use of these substances must
always be by authorized personnel and proper safety procedures must be followed.
• Testing at high voltage (HV). High-voltage tests must only be conducted by authorized
personnel and proper safety procedures must be followed.
Dangerous substances used in winding maintenance are:
• white spirit: solvent
• finishing varnish: solvent and resin
• adhesive resin: epoxy resin
NOTE: There are special instructions for handling dangerous substances during
maintenance work. Important handling instructions can also be found on
warning labels of the packing.
Some general safety measures during winding maintenance are as follows:
• Avoid breathing air fumes; ensure proper air circulation at the work site or use respiration
masks.
• Wear safety gear such as glasses, shoes, hard hat and gloves and suitable protective clothing
to protect the skin. Please refer to the Material Safety Data Sheet (MSDS) provided by the
manufacturer.
• Spray-varnish equipment, the frame of the machine, and the windings must be earthed during
spray-varnishing.
• Take the necessary precautions when working in pits and cramped places.
• Only personnel trained to do high voltage work can carry out a voltage test.
• Do not smoke, eat, or drink at the work site.
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For a test record for winding maintenance, see Section 9, Check Lists.
7.6.2. Timing of the maintenance

There are three main principles for timing the winding maintenance:
• Maintenance of the windings must be arranged according to other machine maintenance.
• Maintenance must be performed only when necessary.
• Important machines must be serviced more often than the less important ones. This also applies
to windings that become contaminated rapidly and to heavy drives.
NOTE: As a rule of thumb, an insulation resistance test must be done once a year.
This must suffice for most machines in most operating conditions. Other tests
must only be conducted if problems arise.
A maintenance program for the complete machine, including windings, is presented in Chapter
7.3, Maintenance program. This maintenance program however, must be adapted to the customer's
particular circumstances, i.e. servicing of other machines and operating conditions as long as the
required servicing intervals are not exceeded.
7.6.3. The correct operating temperature

The correct temperature of the windings is ensured by keeping the exterior surfaces of the machine
clean, by seeing to the correct operation of the cooling system and by monitoring the temperature
of the cooling agent. If the cooling agent is too cold, water may condense inside the machine.
This can wet the winding and deteriorate the insulation resistance.
For air cooled machines it is important to monitor the cleanliness of the air filters. The cleaning
and change interval of the air filters must be planned according to the local operating environment.
The stator operating temperatures must be monitored with resistance temperature detectors.
Significant temperature differences among the detectors could be a sign of a damage in the
windings. Make sure that the changes are not caused by the drifting of the measuring channel.
The alarm and trip temperature limits can be found in Main connection diagram, see Section 5,
Electrical Drawings.
7.6.4. Insulation resistance – measurement and minimum values

During maintenance work and before the machine is started up for the first time or after a long
standstill period, the insulation resistance of stator and rotor windings must be measured. Insulation
resistance is always measured before high voltage testing. The insulation resistance of other parts
can also be measured. The insulation resistance measurement provides information about the
humidity and dirtiness of the insulation. It can also reveal potential insulation damage. Based on
this information, corrective actions - typically cleaning and drying - can be determined. For new,
healthy machines with dry windings, the insulation resistance is very high. The resistance of a
healthy machine can, however, also be extremely low if the machine has been subjected to overly
humid storage conditions, for example.
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In order to be able to evaluate and compare measured insulation resistance values, the values are
stated at 40 °C. The actual measured value is therefore converted to a corresponding 40 °C value
with the help of the following diagram (See Figure 7-4, Correlation between the insulation
resistance and the temperature). The use of this diagram must be limited to temperatures fairly
near to the standard value of 40 °C, since large deviations from this could result in errors. The
general idea is that the insulation resistance value decreases when the winding temperature rises.
The resistance is halved for every 10 - 15 K temperature rise.
Figure 7-4 Correlation between the insulation resistance and the temperature
The same information, as in the figure above, is presented in the table below at 5 degrees steps.
Table 7-8. Correlation between the insulation resistance and temperature values; in degrees
Celsius (°C) and degrees Fahrenheit (°F)
°C 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95
°F 32 41 50 59 68 77 86 95 104 113 122 131 140 149 158 167 176 185 194 203
k 0.065 0.09 0.15 0.175 0.25 0.35 0.55 0.7 1.0 1.5 2.0 3.0 4.0 5.0 8.5 13 18 25 35 50
Either the Figure 7-4, Correlation between the insulation resistance and the temperature or the
Table 7-8, Correlation between the insulation resistance and temperature values; in degrees
Celsius (°C) and degrees Fahrenheit (°F) can be used to determine factor k needed for insulation
resistance value conversion. The conversion is performed in the following manner:
R = Measured insulation resistance value at a specific temperature

k =conversion factor to convert R into R40
R40 = Equivalent insulation resistance at 40 °C
R40 = k x R
Example:
R = 30 MΩ measured at 20 °C
k = 0.25
R40 = 0.25 x 30 MΩ = 7.5 MΩ
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7.6.5. General notes regarding the measurement:

• The windings must be earthed immediately after measurement in order to avoid the risk of
electric shock.
• For specific instructions for each of the component to be measured, see subchapters in Chapter
7.5.6.
• Machines, that are suspected to have a moisture problem, must be dried carefully independent
of the measured insulation resistance value.
• If the measured value is considered too low the machine must be cleaned and/or dried. See
Chapter 7.6.14, Cleaning the windings and Chapter 7.6.15, Drying for details. If these measures
are not sufficient, expert help must be acquired.
• If the values given are not reached, the reason for the low insulation resistance should be
determined. A low insulation resistance value is often caused by excess humidity or dirt,
although the actual insulation is intact.
7.6.6. Minimum values for insulation resistance

The insulation resistance indicated in the FAT test report is normally considerably higher than
the values measured on site. Also typical measured values of a healthy, dry machine can be
considerably higher than minimum limit values. Because insulation resistance varies depending
on the machine type and local conditions, it is wise to follow the insulation resistance value trend
instead of absolute values. The insulation resistance is typically affected by the age and usage of
the machine.
The insulation resistance limits, which are given below, are given in addition to 40 °C (104 °F)
and also for 20 °C (68 °F) for ease of use. The test voltage needs to be applied for 1 minute or
longer.
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For the stator and rotor in addition to general minimum limit values. “First commissioning” values
are given in addition to the general limit values. These values should be attainable during the first
commissioning, if the machines have been stored in dry conditions.
Table 7-9. Normal stator limit values for insulation resistance. The limit values for < 1000 V
can also be used for random wound machines. According to IEC the test voltage should actually
rise as a function of the rated voltage. However, this only has and impact on the PI index (1/10
min).
Winding rated line to Insulation resistance Recommended minim- Recommended minim-

line voltage test direct voltage um insulation resist- um insulation resistance
ance values at 20 °C values at 40 °C
< 1000 V 500 V 20 MΩ 5 MΩ
1000-5000 V 1000 V 400 MΩ 100 MΩ
5000-12000 V 1000 V 400 MΩ 100 MΩ
>12000 V 1000 V 400 MΩ 100 MΩ
Table 7-10. Normal stator limit values for insulation resistance at first commissioning. The
limit values for < 1000 V can also be used for random wound machines. According to the IEC,
the test voltage should actually rise as a function of the rated voltage. However, this only has
and impact on the PI index (1/10 min).
Winding rated line to Insulation resistance Recommended minim- Recommended minim-

line voltage test direct voltage um insulation resist- um insulation resistance
< 1000 V 500 V 1000 MΩ 250 MΩ
1000-5000 V 1000 V 1000 MΩ 250 MΩ
5000-12000 V 1000 V 1000 MΩ 250 MΩ
>12000 V 1000 V 1000 MΩ 250 MΩ
Table 7-11. Normal limit values for a complete main rotor winding with exciter rotor. Also
applies to machines with brushgear, when brushes are lifted.
Rotor rated voltage: Insulation resistance Recommended minim- Recommended minim-

test direct voltage um insulation resist- um insulation resistance
< 1000 V 500 V 6 MΩ 1.5 MΩ
Table 7-12. Normal limit values for a complete main rotor winding with exciter rotor at first
commissioning. Also applies to machines with brushgear, when brushes are lifted.
Rotor rated voltage: Insulation resistance Recommended minim- Recommended minim-

< 1000 V 500 V 200 MΩ 50 MΩ
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Table 7-13. Normal limit values for exciter stators.
Exciter rated voltage: Insulation resistance Recommended minim- Recommended minim-

< 1000 V 500 V 20 MΩ 5 MΩ
Table 7-14. Normal limit values for bearing insulation.
Bearing type Insulation resistance Recommended minim- Recommended minim-

Sleeve bearings, insula- 100 V 400 kΩ 100 kΩ
tion on the shell (if insu-
lation on bearings ped-
estal, lower values can
be accepted)
Kapton insulated bear- 500 V 8 MΩ 2 MΩ
ing shield
Epoxy insulated bear- 500 V 80 MΩ 20 MΩ
ing shield
Table 7-15. Normal limit values for temperature sensors that are not embedded.
Insulation resistance test direct Recommended minimum insu- Recommended minimum insu-
voltage lation resistance values at 20 °C lation resistance values at 40 °C
100 V 40 MΩ 10 MΩ
NOTE: Measurement of embedded sensors is not recommended. However, if these

are measured anyway, the limit for them is 800 MΩ at 20 °C. These limit
values can also be used for other miscellaneous sensors that can be measured
like air gap detectors. In such cases, always check that the sensor can survive
the measurement.
Table 7-16. Normal limit values for anticondensation heaters.
Insulation resistance test direct Recommended minimum insu- Recommended minimum insu-
voltage lation resistance values at 20 °C lation resistance values at 40 °C
500 V 4 MΩ 1 MΩ
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7.6.6.1. Stator winding insulation resistance measurement

The insulation resistance is measured using an insulation resistance meter. Check the test voltage
from tables in Chapter 7.6.4, Insulation resistance – measurement and minimum values. The test
time is 1 minute, after which the insulation resistance value is recorded. Before the insulation
resistance test is conducted, check that:
• The secondary connections of the current transformers (CT's), including spare cores are not
open. See Figure 7-5, Connection of the stator windings for insulation resistance measurements.
part a).
• All power supply cables are disconnected.
• The frame of the machine and the stator windings not being tested are earthed.
• Winding temperature is measured.
• All resistance temperature detectors are earthed.
• Winding temperature is measured.
• Possible earthing of voltage transformers (not common) must be removed.
The insulation resistance measuring must be carried out in the terminal box. The test is usually
performed on the whole winding as a group, in which case the meter is connected between the
frame of the machine and the winding. See part A and part B of Figure 7-5, Connection of the
stator windings for insulation resistance measurements. . The frame is earthed and the three phases
of the stator winding remain connected at the neutral point, see part A of Figure 7-5, Connection
of the stator windings for insulation resistance measurements. . In the figure MΩ represents the
insulation resistance tester.
If the measured insulation resistance of the whole winding is lower than specified, and the phase
windings can easily be disconnected from each other, each phase can also be measured separately.
This is not possible in all the machines. In this measurement, the tester is connected between the
frame of the machine and one of the windings. The frame and the two phases not measured are
earthed, see part C of Figure 7-5, Connection of the stator windings for insulation resistance
measurements. . In the figure MΩ represents the insulation resistance tester.
NOTE: When phases are measured separately, all star-points of the winding system
must be removed. If the star-point of the component cannot be removed, as
in a typical triphase voltage transformer, the whole component must be
removed.
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Figure 7-5 Connection of the stator windings for insulation resistance measurements.
A) Insulation resistance measurement for star connected winding, B) Insulation resistance
measurement for delta connected winding and C) Insulation resistance measurement for one
phase of the winding. MΩ represents insulation resistance meter.
NOTE: After the insulation resistance measurement the winding phases must be
earthed to discharge them.
7.6.6.3. Insulation resistance measurements of the rotor field winding and

exciter
Check the test voltage from tables in Chapter 7.6.4, Insulation resistance – measurement and
minimum values.
When testing the windings of the rotors:
• Disconnect the brush from the slip ring of the earth fault detector if applicable.
• Short circuit the rectifier before measuring.
• Ensure that the stator winding temperature values have been measured. They must be used as
a reference value for the rotor winding temperature.
• Connect the insulation resistance meter between the rotor windings and the shaft of the rotors
as shown in Figure 7-6, Connections for insulation resistance measurements. . The
measurement current must not go through the bearings.
• After the insulation resistance measurement, discharge the windings by earthing them.
When testing the stator winding of the exciter:
• Disconnect the power supply cables from the voltage source.
• Connect the insulation resistance meter between the stator winding and the frame of the
machine as shown in Figure 7-6, Connections for insulation resistance measurements. .
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Excitation machine
Rotor of synchronous 2.
machine MΩ
Synch.
Rectifier
+
motor: ROTOR
Thyristors,
firing
units,
SHAFT
protective
circuits,
starting
resistors
ROTOR
- STATOR
1.
MΩ
Figure 7-6 Connections for insulation resistance measurements.

1. Measurement of windings of the rotors. 2. Measurement of the stator winding of the exciter.
MΩ represents the insulation resistance meter
7.6.7. Polarization index

For the polarization index test the insulation resistance is measured after the voltage has been
applied for 15 seconds and 1 minute (or 1 minute and 10 minutes). The polarization index test is
less dependent on the temperature than the insulation resistance. When the winding temperature
is below 50 °C (122 °F), it may be considered independent of temperature. High temperatures
can cause unpredictable changes in the polarization index, therefore the test must not be used in
temperatures above 50 °C (122 °F).
Dirt and humidity accumulating in the winding normally reduces the insulation resistance, and
the polarization index, as well as their dependence on temperature. Thus, the line in Figure 7-4,
Correlation between the insulation resistance and the temperature becomes less steep. Windings
with open creepage distances are very sensitive to the effects of dirt and humidity.
There are several rules for determining the lowest acceptable value with which the machine can
be safely started. For the polarization index (PI), the values usually range between 1 and 4. Values
close to 1 indicate that the windings are humid and dirty.
The minimum PI value for class F stator winding is more than 2.
NOTE: If the insulation resistance of the winding is in the range of several thousands
of MΩ, the polarization index is not a meaningful criterion of the condition
of the insulation, and it can be disregarded.
7.6.8. High voltage test

A voltage test is used to check for electrically weak spots in the windings that may lead to insulation
failure during servicing. It is carried out during major inspections, troubleshooting and repairs.
DC or AC voltage is used for the high voltage test.
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7.6.8.1. High voltage test for stator winding

An AC voltage test is performed using the following test voltages:
• 1.5 × U[V]
where U = rated line-to-line rms voltage of the stator winding [V].

A DC voltage test is performed using the following test voltage:
1.6 x (1.5 x U)
7.6.9. Fault searching methods
7.6.9.1. Voltage drop test (Rotor winding impedance test)

The main rotor field winding can be tested by applying 100-200 VAC over the entire rotor winding.
The voltage drop across the total winding and each pole winding is measured. The voltage drop
over each pole winding must be the test voltage divided by the number of poles in series. If the
voltage drop measured over the pole windings varies significantly, it may be an indication of a
possible turn-to-turn short circuit, connection error or broken lead.
7.6.10. Tan delta-measurements

Tan delta -measurements are performed only on the stators whose rated line-to-line rms voltage
is more than 4.2 kV.
Tan delta, representing the dielectric and discharge energy losses, is in general measured in steps
of 0.2 U up to the main voltage U. The rate of rise of tan delta as a function of voltage describes
the average partial discharge level both inside and on the surface of the insulation. Thus, it is
difficult to determine the condition inside the insulation.
The tan delta test is done using special equipment and must be performed by experienced personnel.
NOTE: Tan delta measurements cannot be used to estimate the age or predict failure
of the insulation. Only regular trend measurements can reveal more
information.
7.6.11. PD measurements
PD measurements can be useful for high voltage machines, practically when voltage level exceeds
6 kV. PD measurements can be done using various methods, including on-line and off-line methods,
with permanent couplers or with temporarily fitted couplers. PD measurement results are very
prone to noise and challenging to analyse. Some insight can be achieved by following PD
measurement trends. For ABB machines normal periodic maintenance including visual checks is
the most efficient method for winding condition monitoring. If however PD measurements are
performed, most reliable results can be achieved by using ABB LEAP method. LEAP is a service
that includes a number of electrical measurements – such as tan delta, polarization index and PD.
The measurements are done offline. The results produced by ABB LEAP are more stable than
PD measurement results, as each measurement is enhanced by the others and a large database of
earlier tests is used while creating reports.
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7.6.12. Surge comparison test

The surge comparison test detects short circuits or weak points in the turn-to-turn insulation. Steep
voltage pulses are sent to the winding and the oscillations are observed and compared to the results
of other phases. The test must be done only when it is assumed that there is a weak point in the
turn insulation. The test is done using special equipment and must be performed by experienced
personnel.
7.6.13. Visual winding inspection

Winding inspections give information on:
• the rate of contamination; presence of dirt and humidity
• radiator condensation and leakage
• stability of bracings, vibration marks, and cracking
• marks of overheating
• marks of movement
• tightness of the slot wedges
• winding overhangs and their supports,
The results of all inspections must be recorded in the check list supplied in Section 9, Check lists.
When examining the contamination, particular attention must be paid to the open creepage surfaces,
as the insulation resistance is easily affected by the dirt accumulating there. There are open
creepage surfaces, for example, in the brush gear and in connections.
Accumulating dirt blocks the coil gaps and air ducts, and thus diminishes the cooling capacity of
the machine. As a result, the winding temperature rises, and aging may speed up considerably.
Mechanical strain, vibration, and shocks may cause cracks on the edges of the supports, tyings,
and around slot ends. Loose supports and slot wedges are signs of further deterioration. Check
for abrasion marks and powder near the supports, tyings, and at the slot ends. Complete loosening
of the slot wedges and bent coils are serious problems that must be rectified immediately.
Hair cracks and fractures in metal parts such as supporting bolts and squirrel cage windings are
also signs of deterioration, but they take longer to develop into a failure.
Humidity in the winding often causes for example rust on iron, drop marks, dripping, and wetting
marks on dirt layers. Bush-shaped patterns, often charred and left behind by the tracking currents,
warn of an approaching failure. In rare cases, the conductors are corroded.
Marks of the electrical effects (apart from tracking current marks), are usually hidden inside the
slot and conductor insulations.
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Over temperatures that last only for a short period of time can leave marks all over the machine.
The following are marks of overheating:
• Copper in the squirrel-cage windings grows darker (darkening may also be due to the gases
in the environment), and it oxidizes.
• Core laminations of the rotor become blue (over 350 °C [662 °F]) if the temperature rises due
to a jam or an exceedingly heavy start.
• There are color differences in the fastening bolts of synchronous machines.
• Insulation may shrink or split (usually over 200 °C [392 °F]), tyings may crack (over 220 °C
[428 °F]), and polyester film or fibers may melt (over 250 °C [482 °F]).
• Swelling of the slot insulation is also possible.
Prolonged periods over temperatures cause premature ageing. The insulating materials become
brittle and darken in the early stages. As a result, the windings split, disintegrate, and fracture.
7.6.13.1. Corrective actions based upon the observations

According to the observations the following conclusions can be drawn for necessary actions:
Observation Action
Degree of contamination
- a lot of dirt, cooling ducts about to be clogged - cleaning and drying, if necessary
- conductive dirt, low insulation resistance - cleaning and drying, if necessary
- humidity, low insulation resistance - drying
Finishing varnish:
- mat, worn, cracked - cleaning and revarnishing
- coming off - removing old varnish and revarnishing
Supporting parts:
- loose slot wedges - tightening *
- vibration marks - tightening, strengthening and revarnishing *
- bent coils - strengthening or rewinding *
- supporting blocks - renewed *
Ageing:
- darkening, slight embrittlement - cleaning and revarnishing
- embrittlement, loose insulation layer - rewinding*
* = A statement from an expert is needed
7.6.14. Cleaning the windings

If dirt has accumulated in the open creepage surfaces, it must be removed. This must always be
done when re-varnishing the windings because a new varnish coat will trap any existing dirt
beneath it.
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7.6.14.1. Cleaning methods

The windings can be cleaned using the following methods.
Blowing and vacuuming

Blowing and vacuuming are used if the dirt is dry and can be removed easily. Vacuuming is a
requirement, since blowing tends to redistribute the dirt or move it deeper between the insulation
layers.
CO2 cleaning, dry ice cleaning

CO2 cleaning is an efficient cleaning method for jobs done in the field. However, if the dirt
consists mainly of grease or oil, CO2 cleaning may not be effective. In such cases, cleaning
attempts may have a poor result or in the worst case it may only redistribute the grease and dirt
into the stator air ducts clogging the cooling channels. For the best results in the presence of grease
and oil contamination, consider pre-cleaning the heavily contaminated areas by wiping the windings
with a suitable detergent before attempting C02 cleaning.
Wiping
Wiping is used when spray-wash is not possible. Wipe the surfaces that can be reached easily
with a cloth dampened with detergent. In cramped areas of the windings, a special brush may be
more effective. Low insulation resistance is often caused by dirty slip rings and brush gear, so
the creepage surfaces on these components must be carefully cleaned.
Spray wash
A spray wash is carried out with an airless high-pressure spray or a conventional spray. A
high-pressure spray is more effective in removing dirt. The detergent used must remove the dirt
without softening or damaging the insulation. Use large amounts of cleaning agent.
Dip wash
A dip wash can be used if the chosen detergent does not soften or damage the insulation. Since
the dirt is not removed mechanically, a very effective cleaning and scouring agent must be used.
A long dipping time may be required.
Water wash
A water wash involves rinsing with water to prevent the detergents from penetrating into places
from where they cannot be removed. Do not wash with water before all other cleaning methods
described above have been tried. A list of suitable detergents can be found in Chapter
7.6.14.2, Cleaning agents.
After washing, rinse the windings with pure water several times. Distilled or deionized water must
be used for the last rinse.
Dry the windings after the water wash.
7.6.14.2. Cleaning agents

Some features of the permitted detergents are described in Table 7-17, Features of the detergents
for the winding.
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Before any cleaning agent is used, its damaging effect on the old winding surface must be checked.
A suitable test can be performed as follows:
1. Rub the tested surface for five minutes using a cloth and the cleaning agent. Make sure that
the surface remains completely wet during this time.
2. Try to remove the varnishing using for example your thumb nail.
3. For comparison, try to remove the varnishing on a dry part of the surface
If the surface layer feels soft or can be removed easily, the cleaning agent is too strong.
For minimal environmental loading, water or water-detergent mixtures must be used when possible.
If the dirt contains water soluble agents, water must be used.
Substances that improve the cleaning power must be added to the water to dissolve grease-
containing dirt. Make sure that a detergent does not leave electrically conductive residues on the
surfaces.
Water soluble solvents, such as acetone and isopropyl alcohol, can also be used to improve the
cleaning effect. Note that such solvents increase the flammability of the mixture.
If organic solvents are to be used, cleaning agents based on aliphatic hydrocarbons are required.
Several manufacturers of cleaning solvent mixtures are presently developing such halogen-free
cleaning agents, to replace the chlorinated solvent mixtures used in the past.
White spirit is the most common organic solvent. It is a good solvent for greases but quite inefficient
for pitch-like dirt on the windings (produced by coal and burning residues of diesel oil and
humidity). White spirit is also flammable (flash point 30 - 40 °C [86 - 104 °F]).
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Table 7-17. Features of the detergents for the winding
Detergent name Water Water Isopro- White Acetone Xylene

(hot) (hot) + de- pylene spirit
tergent alcohol
140/200
1:20 in
volume
Class of flammable Incom- Incombust- 1 11 1 11
liquids bustible ible
DIRT dissolving or Pitched diesel 1 1-3 2 2 3 3 0: Does not clean
reducing effect grime, fats, oils
1: Removes dirt poorly
Salts 3 3 0 0 0 0
2: Cleans reasonably
Greasy pulpwood 0 2 1 2 2 2
3: Cleans well
Greasy coaldust 0 2 2 3 3 3
Normal dust 2 3 1 3 1 1
VARNISH OR Silicone rubber 3 3 3 2 0 1 0: Does not resist the
RESIN dissolving Epoxy and polyester 3 3 3 3 3 3 solvent
or softening effect resin
1: Poor resistance of
Red varnish (epoxy, 3 3 3 3 2 2 solvent
alkyd) 2: Satisfactory resistance
of solvent
3: Good resistance of
solvent
7.6.15. Drying
The windings must be dried:
• after washing (especially a water wash and rinse)
• if they have become humid in use or during a standstill.
Drying must always be started with an external blower or warm air. Other means should only be
attempted if a blower and warm air do not suffice.
During drying, the rate of temperature rise of the winding must not exceed 5 K (9 °F) per hour,
and the final temperature must not exceed 105 °C (220 °F). A sudden temperature rise or a too
high a final temperature can cause steam to be formed in the cavities of the windings, which can
in turn destroy the windings. During the drying process, the temperature must be monitored
periodically, and the insulation resistance must be measured at regular intervals.
A very wet machine must be dismantled and the windings dried in an oven. Every part must be
checked. If the machine is not very wet, the winding can be dried by passing a current through it.
If the winding is dried by passing a current through it, the source of electricity can be for example
a welding machine or a similar device.
NOTE: Direct current or alternate current can be used. The current must not exceed
25 % of the nominal current, which is indicated on the rating plate on the
machine. The winding temperature must also be continuously monitored.
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When drying in an oven, the temperature rise and the maximum temperature must be monitored
carefully. The oven temperature must be around 90 °C (194 °F) for 12 to 16 hours and then 105
°C (220 °F) for six to eight hours. These times can vary, and the correct time must be monitored
with an insulation resistance test.
Effective drying is achieved with the right balance of heat and ventilation. The air circulation
inside the machine must be as effective as possible.
Drying in an oven with good ventilation is the most effective technique. Unfortunately, this is not
usually possible at the machine's operating site. Therefore, either hot-air-blow or heating the
windings with current must be used. Adequate fresh-air circulation is essential, whatever heating
method is used.
An insulation resistance test must be performed after drying the windings. When drying is started,
the insulation resistance decreases due to the temperature rise. As the drying continues, however,
the insulation resistance increases until it reaches a stable value.
7.6.16. Partial discharges

Partial discharges (PD) are a normal phenomenon in medium and high voltage rotating electrical
machines (rated voltage several kV). The thickness of insulation in rotating electrical machines
is relatively small compared to the voltage stress, which leads to a relatively high electrical field
strength. The breakdown strength of gas (air) can be locally exceeded on the surface of the
insulation and inside small gas filled cavities (diameter in micrometers) existing inside the
insulation layers. This leads to very weak sparking in the gas, known as partial discharge. Due to
this, ABB has created an insulation system that is very resistant to partial discharges.
Despite that insulation is designed to withstand even a very high partial discharge activity, a very
high partial discharge level can be a symptom of a problem in insulation, for example contamination
of the end winding surfaces, which makes winding surfaces electrically conductive or hydroscopic.
When rated voltage is very high, stress grading taping is used in addition to conductive slot corona
protection taping. The stress grading tape is applied on coil ends as an extension to the conductive
taping. This prevents sparking on the end of the conductive taping by smoothening the surface
potential (voltage) distribution on the surface of the coil. At low rated voltages the conductive
and stress grading tapings are not needed. When conductive taping is used, part of it is visible
near the slot ends of the stator core. The conductive tape is black. The stress grading tape is not
visible because it is covered by the red surface tape of the coil.
At low rated voltages the conductive and semiconducting tapings are not needed.
When conductive taping is used, part of it is visible near the slot ends of the stator core. The
conductive tape is black. The semiconducting tape is usually not visible because it is covered by
the red surface tape of the coil.
In some cases it is possible that measured pulse patterns caused by partial discharge may reveal
signs of partial discharges be seen on the coil surfaces. If this happens, the conductive tape used
on the slot sections of the coils, or the red surface tape used on coil ends, has been partly eroded
by partial discharge. This can be caused by deterioration of contact surfaces between different
tapings or due to relatively weak contact the ground potential. Also minor differences in
manufacturing, like for example exact distance of metallic support structures to coil, can cause
differences in the PD erosion pattern. The eroded area is visible and it typically appears gray or
white and dusty. The netlike polyester fabric of the conductive or surface tape is also usually
visible.
The eroded area is typically gray or white and dusty. The netlike polyester fabric of the conductive
or surface tape is also usually visible.
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It is recommended that the eroded conductive tape is is serviced within a few years after detection
of PD erosion, for example during a scheduled service stop, to reduce the discharges. If the eroded
tape is not serviced and discharges are intensive, the insulation might in the long run age somewhat
faster than usual or the metal parts can be corroded due to the ozone created by the discharges.
Depending on situation PD servicing work may include painting of surfaces with semiconductive
or conductive paint, changes in insulation distances or change of connection and star point. Detailed
service instructions are available from ABB by request, for contact information see Chapter 9.1.5,
Global Technical Support Center Finland contact information. ABB is also able to provided
various PD detection measurement services, both for on-line and off line measurement.
7.6.17. Varnishing of the windings

A finishing varnish is a varnish or a resin coat that is sprayed or brushed on the insulation. It is a
protective layer that seals the windings, improves tracking resistance and makes cleaning easier.
In new machines a finishing varnish treatment is optional.
The finishing varnish can crack or peel after a long operating time. Re-varnishing is necessary
when:
• the old finishing varnish flakes, cracks or peels off.
• the surface of the winding is rough (dirt sticks to it easily).
The windings must be cleaned carefully before a new coat of varnish is applied, so that no dirt
will be left under the new coat. Old finishing varnish that can come off easily must be removed
before re-varnishing.
Varnish is usually applied with a spray (one or two coats suffices). If the windings are still warm
after drying, wait until the temperature of the windings is below 40 °C (104 °F). Apply the varnish
between the coils and other parts that are not easily reached. Avoid thick coats of varnish as they
dry slowly. Rotating parts must be left to dry for at least 24 hours at room temperature before
bringing them into use. Solvent fumes from the varnishes are generally poisonous and flammable,
so safety at work must be taken into account.
The normal exciter winding resin surface has some cracks on it. These cracks are normal and do
not require servicing. The cracked exciter winding surface can be cleaned and re-varnished.
7.6.18. Other maintenance operations

Most ABB-made windings are trouble-free and, in addition to periodical monitoring, they require
only occasional cleaning and drying as described above. If extraordinary circumstances occur and
other maintenance is required, professional help must be sought. The warranty will remain in
force during the warranty period only if the machine is serviced in accordance with the maintenance
program. The ABB Global Service Center organization is happy to assist in questions regarding
the maintenance of electrical machine windings, for contact information see Chapter 9, Global
Technical Support Center Finland and life cycle services.
7.7. Maintenance related to electrical performance, excitation, control, and

protection
The electrical performance of a synchronous machine is mostly defined by the condition of the
rotor and stator windings and the operation of the excitation system. The main machine winding
maintenance is described in Chapter 7.6, Maintenance of stator and rotor winding. In this chapter,
the focus is on the maintenance of the excitation system and the control and protection systems.
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7.7.1. Exciter insulation resistance measurement

The insulation resistance in the exciter can be tested with the winding insulation resistance test.
The procedure is described in detail in Chapter 7.6, Maintenance of stator and rotor winding.
Check the test voltage from tables in Chapter 7.6.4, Insulation resistance – measurement and
minimum values. The test must be performed in the terminal box after the cables have been
disconnected. The connection is shown in Figure 7-7, Connection for exciter stator insulation
resistance test .
The resistance of the exciter rotor is usually measured jointly with the rotor of the main machine,
see Chapter 7.6.6.3, Insulation resistance measurements of the rotor field winding and exciter.
The resistance of the exciter rotor can also be measured separately, but this requires special
arrangements.
Figure 7-7 Connection for exciter stator insulation resistance test

(MΩ represents insulation resistance tester)
7.7.2. Protection trips

The synchronous machine needs to be protected with alarms and trips in the case of abnormal
running conditions, both electrical and mechanical. Some of these protections can be reset and
the machine restarted directly as the fault is located.
Alarms or trips in the following protections must be further investigated:
• Diode fault protection, see Chapter 7.7.6, Diode fault.
• High temperature in bearing, see Chapter 7.5, Maintenance of lubrication system and bearings.
• High temperature in winding or in cooling air, see Chapter 7.6, Maintenance of stator and
rotor winding and Chapter 7.7, Maintenance related to electrical performance, excitation,
control, and protection.
• Over current, current unbalance, bus bar voltage.
• Vibration protection, see Chapter 5, Commissioning.
7.7.3. Maintenance of Automatic Voltage Regulator (AVR)

When the systems is at a standstill the screwed terminals must be checked for tightness. Dusty
cooling flanges must also be cleaned.
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Unit must not be opened. Defective unit must be sent to the manufacturer for repairing. In such
a case the following information must be attached:
• the serial number of the AVR
• the serial number of the generator in which the AVR is installed
• the problem noticed in the AVR
• which operation condition is concerned
• which operation mode is concerned.
7.7.4. Pt-100 resistance temperature detectors

Pt-100 resistance temperature detectors are an essential part of the machine's monitoring and
protection system. They are used to measure the temperature of the windings, bearings and the
cooling air. The Pt-100 detectors use a fine platinum filament for measuring the temperature.
They must be handled carefully as they can be damaged, for example by incorrect handling or
excessive vibration.
The following symptoms might suggest a problem in a Pt-100-detector:
• Infinite or zero resistance over the detector.
• Disappearance of measurement signal during or after start up.
• A significantly different resistance value one of the detectors.
If a Pt-100 failure is suspected, always confirm the finding from the connection box. This can be
done by measuring the resistance over the detector. Register the findings in the Pt-100 Failure
Inspection Protocol found in Section 9. For the correct measuring current and resistance values
at different temperatures see Section 7, Accessory Information and the appropriate Pt-100 detector.
There are two possible remedies for a Pt-100 detector damage. If there are operational spare
detectors remaining in the stator winding, they can be taken into use. If all the working factory
assembled detectors are in use a new detector can be retrofitted in the winding end. Contact ABB
for further information.
7.7.4.1. Pt-100 temperature detector retrofitting
Introduction
The temperature detectors are installed between the two coils of a stator slot. Due to the location,
the detectors are not replaceable, and additional identical temperature detectors cannot be added.
For more information about temperature detectors, see Section 7, Accessory Information and the
Pt-100 elements.
However, coil surface mounted temperature detectors can be installed. As the location of these
sensors is different, they will show a slightly different temperature. The difference between a
retrofit and the original sensor will depend on many factors e.g load, ambient temp, position etc.
If a retrofit sensor is used alarm and triggering set points need to be lowered or measured values
compensated. Suitable set points can be checked by the running machine at 100% load.
Pt-100 retrofitting should be considered only if no spare Pt-100 elements are available.
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The instructions below describe how to add coil surface mounted detectors to the stator winding
slot exit area. The purpose of these instructions is to provide an overview of the work – it is
recommended that the actual work is done by an ABB Service engineer familiar with the retrofitting
process. The ABB Service engineer also hs machine-specific installation parts, materials safe for
windings and detailed instructions.
Installation place
The copper lead in a stator coil is fully insulated through the whole coil, and the surface potential
of the coil inside the stator core is very close to the potential of the stator core. However, the
surface potential of the stator winding increases rapidly after the coil exits the stator core, and it
is therefore important to try to place the temperature detector as close to the stator core as possible.
The temperature detector should be installed on the coil that is electrically close to the stator
winding star point.
Preparing installation
Before installing a temperature detector, verify that it functions properly.
NOTE: Temperature detectors, for example the Pt-100, must be installed near the
stator core, see Figure 7-8, Temperature detector installation place.
Figure 7-8 Temperature detector installation place
To install the temperature detector:
1. Choose a coil of the required phase. The coil must be electrically close to the stator winding
star point in order to minimize voltage stress.
2. The sensor should have contact with the slot corona protection tape if such tape exists. If
necessary, use conductive paint to create the contact area. Paint a small area, approximately
30 mm, with conductive paint. The overlap of the paint with the conductive tape should be
at least 5 mm.
Installation
A good thermal contact between the coil and the detector is essential when the temperature detector
is placed on the stator winding, as the purpose of the temperature detector is to monitor the
temperature of the coil, not the surrounding air. Therefore the temperature detector must be placed
as close to the coil surface as possible.
1. Place the temperature detector on the coil using silicone padding of 10 mm around the
detector.
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2. Cover the temperature detector with polyester felt with a total thickness of approximately 6
mm. This will ensure that the detector is not cooled by the ambient airflow.
3. Bind and impregnate the felt using glass or Terylene tape and air-dry polyester or epoxy
resin, see Figure 7-9, Temperature detector and cover must be impregnated and bound
tightly.
Figure 7-9 Temperature detector and cover must be impregnated and bound tightly
7.7.5. Insulation resistance measurement for auxiliaries

To ensure correct operation of the machines protections and other auxiliaries, their condition can
be determined by an insulation resistance test. The procedure is described in detail in Chapter
7.6, Maintenance of stator and rotor winding. Check the test voltage from tables in Chapter 7.6.4,
Insulation resistance – measurement and minimum values. The insulation resistance measurement
for Pt-100 detectors is not permitted.
7.7.6. Diode fault

If a diode in the rotating rectifier fails, the generator must be tripped. To determine and locate a
faulty diode:
1. Open the covers at the non-drive end of the machine and measure the insulation resistance
with an ohm-meter over one of the diodes.
2. If diode failure is detected, disconnect all diodes and test them separately to locate the faulty
diode.
NOTE: Do not open the service covers or end shields unless it is certain that the
machine is isolated from its driving source.
To replace faulty diodes:
1. Open the service doors at N-end shield of the machine.
2. Disconnect the wires connected to the diodes and exciter winding connection cables. See
the diode bridge/thyristor bridge drawing in Section 5, Electrical Drawings.
3. Check the condition of the diodes by measuring the resistance over a diode in both directions.
4. Replace the damaged diode(s).
5. Clean the contact surfaces, and apply electric joint compound.
6. Fasten the diode(s). Bind the connection leads of the diodes as on original assembly.
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7. Check fastening and locking of all rectifier bridge components.
8. Make sure that no tools etc. are inside the machine and close the service covers.
Figure 7-10 LND SD600N22P diode in the rectifier bridge
After replacing the diodes, the condition of the diodes can be checked by comparing no-load
excitation current to commissioning values. A diode failure results as a significant increase in
excitation current.
7.8. Maintenance related to thermal performance and cooling system

An increase in the machine's temperature is usually caused by:
• a decline in the effect of the cooling system

or
• excessive amounts of heat produced by the machine.
If the machine temperature exceeds normal values, determine which of these two causes is
responsible for the increase in the temperature. Excessive heat production might be caused, for
example, by a winding problem or by network unbalance. In such cases, corrective actions on the
cooling system would be ineffective or harmful.
7.8.1. Cooling System

The machine is cooled with a shaft mounted fan. The cooling air is taken in from the surrounding
air through air filters and it is blown out from the top of the machine (IC 0A1), see Figure ???.
The cooling air must be as clean as possible, because dirt that drifts into the machine causes
contamination and reduces the efficiency of the cooling.
The air filters are self charging electrostatic panels of type Pliotron CR. They are made of washable,
woven polyethylene fiber and incorporate a non-woven synthetic fiber mat. They are enclosed in
a rust-resistant galvanized steel-frame and reinforced with 1/2" mesh galvanized steel hardware
cloth. Their maximum operation temperature is +100 °C.
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If winding or cooling air temperature detectors show an abnormal temperature, the cooling system
has to be checked. Either of the following two reasons could be causing the problem in the cooling
system:
• problems with air filters

Check the condition of the air filters.
• problems in air circulation inside the machine

Ensure good air circulation inside the machine. The machine interior must be cleaned and
checked during overhauls or if problems arise. For more information see Chapter 7.8.1.1,
Cleaning
If the winding or cooling air temperature detectors show an abnormal temperature, the cooling
system has to be checked.
Other possible causes for poor cooling system performance include elevated ambient temperature
or high intake air temperature. In addition, lubrication or bearing malfunction might lead to high
bearing temperature.
A seemingly high temperature might also be caused by a problem in the temperature measurement
system, see Chapter 7.7.4.1, Pt-100 temperature detector retrofitting.
Figure 7-11 Air cooling
7.8.1.1. Cleaning
The filters must be cleaned on a regular basis. When the temperature detectors in the winding
show abnormal temperature or approach the alarm level, the filters have to be cleaned. If a pressure
manometer is used, the filters have to be cleaned when the pressure drop has doubled.
Remove the air filters for cleaning. They must regularly be cleaned by vacuuming first from the
upstream side, then on the discharge side. Periodically, a thorough wash with clean water must
be undertaken to release any dirt not removed by vacuuming. When heavy grease concentrations
are encountered, the filters must be washed with a detergent solution. This solution must be rinsed
thoroughly before returning the filter to service. Be careful to install the air filters back the right
side out (arrows on the air filter frame indicate the direction of air flow). Refer also to air filter
manufacturer information.
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Chapter 8 Troubleshooting
This chapter is intended as a help in the event of an operational failure with an ABB delivered
machine. The troubleshooting charts given below can aid in locating and repairing mechanical,
electrical and thermal problems, and problems associated with the lubrication system. The checks
and corrective actions mentioned should always be conducted by qualified personnel. If in any
doubt, the ABB Service should be contacted for more information or technical assistance regarding
troubleshooting and maintenance.
NOTE: In case the operational failure has been such that any of the rated parameters
has been exceeded, the machine needs to be inspected by a competent person
prior restart. Examples of such failures include over speed, over temperature,
loose items found.
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8.1. Mechanical performance

Troubleshooting
Mechanical performance
Experienced
malfunction
Vibration
Noise
Possible cause Corrective action
Check lubricant quality and quantity and
x x Lubrication malfunction
lubrication system function
Damaged bearing Check bearing condition and replace bearing
x x
parts parts
Bearing malfunction
Faulty bearing
x x Open and readjust the bearing
assembly
Imbalanced or
x x Faulty cooling fan(s) Check and repair cooling fan(s)
damaged fan(s)
x Malfunctioning cooling system Inspect and repair cooling system
x Malfunctioning excitation system Inspect and repair excitation system
x x Machine misalignment Check machine alignment
x x Rotor or shaft imbalance Rebalance rotor
Check rotor wedges, poles etcx, repair and
x x Loose parts in rotor
rebalance rotor
Check the balance of connected machinery
x x Vibration coming from connected machinery
and coupling type
Check alignment and coupling function and
x x Axial load coming from connected machinery
type
x x Faulty or incorrectly assembled coupling Check coupling function
x Insufficient foundation strength Reinforce foundation as per ABB instructions
x Main machine or exciter winding fault Check main machine and exciter windings
Check that network balance fulfils
x x Excessive network unbalance
requirements
x x Bearing misalignment Check bearing pedestal alignment
Foreign material, moisture or dirt inside the Check and clean machine interior, dry
x
machine windings
x x Airgap not uniform Measure and adjust airgap
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8.2. Lubrication system and bearings
8.2.1. Lubrication system and sleeve bearings

Troubleshooting
Lubrication syﬆem and sleeve bearings with oil supply
Experienced
malfunction
Bearing noise or vibration

High bearing temperature
Visibly poor oil quality

Oil inside the machine
Oil leaks

x x x Insufficient Oil flow malfunction Check oil pump, oil reduction valve and oil filter
x lubrication Oil viscosity too high Check oil temperature and oil type
x x x x Unsuitable oil quality Check ABB oil recommendations
Check lubrication system and adjust oil
x Oil inlet temperature too high
temperature
Oil quality is
Incorrect oil change
x x Clean bearing and change oil
reduced
period
Faulty coupling or
x x x x Excessive axial load Check coupling, mounting and alignment
mounting
x x x Machine misalignment Realign machine
Verify correct bearing assemblage and
x x Incorrectly assembled bearing
adjustments
Change oil, check bearing condition, replace
x x x Oil impurities
bearing shells
Restore bearing insulation, replace bearing
x x Bearing currents
shells
Damaged bearing
x x shells Complete bearing failure Replace bearing parts
x x Normal wearing Replace bearing shells
x x Operating speed too low Check the operating speed range of bearing
Faulty Faulty temperature Check bearing temperature measurement
x
instrumentation detector system
x Damaged or worn-out bearing seals Replace bearing seals
x Oil flow too high Faulty regulator settings Check and correct oil flow
Problem in oil return
x Faulty oil piping Check oil return pipe inclination
flow
Rotating equipment Check pressure levels, relocate rotating
x External vacuum
nearby equipment
Internal over Pressure compensation
x x Remove cause for internal over pressure
pressure failure
x Damaged machine seal Replace or repair machine seal
Faulty assembled or maintained lubrication Check pipeline connections and oil filter
x
piping tightness
x x Foreign matter inside the bearing Clean bearing and check seal condition
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8.3. Thermal performance
8.3.1. Thermal performance, open air cooling system

Troubleshooting
Thermal performance, open air cooling syﬆem
Experienced
malfunction
High cooling air

High winding
temperature
temperature

Ambient temperature too Add ventilation to decrease ambient
x x
high temperature
High intake air Ensure sufficient clear distances surrounding
x x Exiting air is pulled back in
temperature the machine
Place heat sources further away, check
x x Heat source nearby
ventilation
x x Dirty machine interior Clean machine parts and air gaps
Inspect cooling arrangement condition and
x x Faulty cooling arrangement
Faulty air flow correct assembly
x x Air intakes are blocked Clear air intakes of debris
x x Air filter is clogged Clean or replace air filters
x x Damaged cooling fan(s) Replace fan(s)
Replace fan(s) or change rotating direction of
x x Cooling fan rotating in the wrong direction
external fan
x Overload Control system setting Check machine controls, eliminate overload
Check actual speed and ABB speed
x x Overspeed
recommendations
Check that network balance fulfils
x Network unbalance
requirements
Faulty instrumentation or measurement
x x Check measurements, sensors and wiring
system
x Main machine or exciter winding fault Check main machine and exciter windings
NOTE: For high bearing temperature, see Table 8.2, Lubrication system and bearings.
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8.4. Electrical performance
8.4.1. Electrical performance and excitation system of generators

Troubleshooting
Electrical performance and excitation syﬆem of generators with transformer excitation
Experienced malfunction
Increase in excitation current

Malfunction during start-up
Operation not adjustable

Faulty parallel operation
Performance deviation
Lost excitation
Possible Cause Corrective action

x x Abnormal speed Faulty speed control Check speed control of operating machine
x x Network phase unbalance Check that network balance fulfils requirements
x Speed variation of operating machine Check speed control of operating machine
Check excitation panel relay and voltage regulator
x x Faulty settings
setting
Field application
x x Faulty wiring Check excitation panel control cubicle and generator
failure
Demagnetised excitation See main connection diagram to restore permanent
x x
magnet magnet excitation
Check transformer winding insulation resistance and
x x x x Defective voltage transformer
connections
x x x x x Defective parallel operation transformer
connections
x x Defective current transformer
connections
x x Short circuit excitation system failure Check operation of short circuit excitation system
Check main machine winding and insulation
x Main generator winding fault
resistances
x x Excitation system winding fault Check exciter winding and insulation resistances
Check connection and condition of rectifier
x x x x x Faulty rotating rectifier
components
x x x x Faulty wiring in excitation system Check electrical connections in excitation system
Excitation
x x Excitation panel equipment Check and replace excitation panel equipment
equipment fault
x x x x x x Faulty AVR settings Check and adjust voltage regulator settings
Bad AVR tuning Voltage oscillation, poor
x Check AVR tuning (PID parameters)
parameters response
x x x x x x Defective AVR Check and replace voltage regulator
x x x x x x Faulty AVR wiring or incorrect connections Check AVR wiring and connections
x Power factor variation over permitted values Check AVR condition
Check connections and condition of voltage
x x x Faulty external voltage reference system
reference
Check actual value measurement system and
x x No actual value information for AVR
electrical connections
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Chapter 9 Global Technical Support Center Finland and life cycle

services
9.1. The Global Technical Support Center Finland

The Finnish Global Technical Support Center provides fast and effective product support to ensure
that ABB motors and generators deliver the fullest possible reliability, availability, maintainability,
and safety troughout their service life. Support activities for rotating electrical machines
manufactured by ABB and Strömberg have been based in Helsinki, Finland since 1889.
9.1.1. Site Services

The Site Services department provides:
• Installation and commissioning
• Maintenance and inspections
• Troubleshooting and servicing
• Upgrading and modification services.
9.1.2. Spare Parts

The Spare Parts department:
• Co-ordinates spare parts packages delivered with the machines
• Sells genuine OEM spare parts after the machines have been delivered.
For information on the spare part packages, see Chapter 9.2, Spare parts.
9.1.3. Support and Warranties

The Support department:
• Handles warranty issues under warranty period based on written claims
• Makes warranty determinations
• Decides about corrective actions
• Makes and executes a resolution plan
• Collects and gives feedback to R&D and production units.
• Provides technical support
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9.1.4. Support for Service Centres and partners

Authorized Service Centres locations and ABB's partners are assisted with questions concerning
the mechanical structure as well as in the handling of electromagnetic and insulation technology
issues.
9.1.5. Global Technical Support Center Finland contact information

Our service staff is available to serve you by telephone at +358 10 22 21999 (24h):
Other means of contact we offer for our

customers' convenience are:
E-mail for spare parts and site services: machines.service@fi.abb.com
E-mail for warranties and technical support: support.machines@fi.abb.com
NOTE: Please add the serial number of the machine (seven digits, starting with '45'
or '46') to your e-mail for reference information.
9.2. Spare parts
9.2.1. General spare part considerations

All machines manufactured by ABB are designed and manufactured to provide reliable and
trouble-free operation for decades. This requires, however, that the machines be properly maintained
and operated. This maintenance includes changing of parts subjected to normal wear.
Inevitably, there is a certain amount of uncertainty related to wearing; the wear rates of these parts
vary greatly with the application, environment and specific conditions of use. Therefore, the
condition of these parts should be checked regularly, and quantities of spare parts should be kept
in stock, to help to minimize down time if the need arises. The extent of the stock should be
decided in view of the importance of the application, the availability of the spare part in question
and the expertise of the local maintenance personnel.
9.2.2. Periodic replacement of parts

There is always mechanical wear when two moving surfaces are in contact with each other. In
electrical machines most of the mechanical wear occurs between the rotating shaft and stationary
parts. Bearing components, such as bearing shells and oil rings in sleeve bearings, will eventually
wear out and need to be replaced, even if correct lubrication is maintained. Other parts that
experience include seals that are in constant contact with the rotating shaft, and the brushes, brush
gears and slip rings of the slip ring unit.
The parts mentioned above make an extensive, but not a exhaustive, list of the mechanically
wearing parts. These parts are provided with a life time estimate, but, as mentioned earlier, their
actual durability can vary significantly. For this reason, at least these parts should be kept in stock.
It should also be noted that their replacement in response to normal wear, is not covered by the
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9.2.3. Need for spare parts

Other types of wear may occur, as a result of elevated temperatures, electrical disturbances, and
chemical reactions. Wear to the diodes in the rectifier bridge is usually linked to electrical operating
conditions. It is usually a slow process, but it is strongly dependent on the operation conditions
in which the machines are operated.
Air filters, which protect the machine interior from contamination, eventually become saturated
with impurities from the air and need to be replaced, to ensure the correct operation of the cooling
unit and the continuous protection of sensitive components.
The electrical windings of the ABB machines feature good protection against wear, but this is
effective only in combination with appropriate maintenance and operating conditions. The design
operating temperature must not be exceeded and the windings must be cleaned from dirt regularly.
The winding may be subjected to accelerated wear also as a result of electrical disturbances of
various kinds.
The machines feature stator winding Pt-100 temperature detectors located inside the stator core
slots. Because these detectors cannot be replaced, we have provided spare Pt-100 detectors
ready-installed in the stator winding. These spare detectors can be brought into use if the primary
detector fails. If the spare detector should fail, one possible corrective action is to add Pt-100
detectors at the stator winding end. Please consult ABB for further information.
9.2.4. Selection of the most suitable spare part package

The most suitable package should be selected in view of application's criticality and financial
risks related to the amount of downtime and loss of production. Below standard sets are presented
assuming installation of one electrical machine. In case there is more similar machines, less spares
can be kept in stock. Simple thumb rule is to keep one set for every 3 machines.
• Operational package (Sometimes known also as safety package, emergency package or

consumable package) should always be available and replenished when used. In contains parts
for normal wear and tear, as well as parts for recovery from most common potential failures
and commissioning. It should be available as minimum for L1 maintenance.
• Recommended package (Sometimes known also as Complete preventive maintenance package),

recommended to be kept available for L1-L4 maintenance and generally for improved failure
recovery time in critical machines. Package contains all items that can be purchased separately
for each maintenance from L1 to L4 separately.
• Capital spare parts, enable fast recovery even in case of serious failure like overspeed.
Recommended for very critical installations. Option is to keep a complete machine as a capital
spare part.
In addition to spare parts, maintenance requires general and special tools. Most critical tools are
mentioned in the Maintenance section of the manual. The extension shaft for removing the rotor
is a special tool that is recommended to be ordered from ABB.
9.2.5. Typical recommended spare parts in the individual sets

Below we provide a general recommendation of the typical spare parts for various packages. To
receive a quotation for specific parts for a specific machine, please contact the ABB Service.
Please note that, even though ABB has tailored the spare part sets to match the machine, their
documentation may contain references to accessories not found with all machines.

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9.2.5.1. Operational package
Main machine
Spare part Amount

Automatic voltage regulator (AVR) 1 pc.
Rectifier diodes Set
DC bridge protective circuits Set
Air filters Set
Pt-100 for cooling air 1 pc.
Cooler/top module damping elements and seal- Set
ing gaskets
Shaft earthing brushes and shaft earth fault pro- Set
tection brush (if applicable)
Lubrication system and bearings
Spare part Amount

Bearing RTD 1 pc.
Bearing labyrinth seal 2 pcs.
Bearing shell, for D-end and ND-end 1 pc.
Bearing oil ring 1 pc.
Oil lubrication and jack-up unit filter Set
9.2.5.2. Recommended package
Main machine
Spare part Amount

Safety package (without AVR) 1 pc.
AVR with board 1 pc.
Voltage transformer 1 pc.
Short circuit current transformers 3 pcs.
Actual value current transformer 1 pc.
Cooler cleaning tool set 1 pc.
Stator current measurement transformers 3 pcs.
Anticondensation heater 1 pc.
Cooling air temperature detectors 1 pc.
Internal cable transit set 1 pc.
Crimp connection replacement set 1 pc.

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9.2.5.3. Capital spare parts

Spare part Amount
Exciter rotor 1 pc.
Exciter stator 1 pc.
Rectifier bridge 1 pc.
Rotor pole 2 pcs.
Rotor (complete) 1 pc.
Stator with frame 1 pc.
Water cooler element 1 pc.
9.2.6. Order information

To ensure fast and correct spare part order and delivery, our ABB Service personnel should be
provided with the serial number of the machine in question. The serial number can be found either
on the rating plate fixed to the machine's frame, or stamped on the frame. It is also given in this
manual.
In addition, provide specific and detailed information about the parts ordered (in most cases this
information can be found in Section 7, Accessory Information. The contact information of the
ABB Service's organization can be found in Chapter 9, Global Technical Support Center Finland
and life cycle services.

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Chapter 10 Disposal and recycling instructions
10.1. Introduction
ABB Oy is committed to its environmental policy. We strive continuously to make our products
environmentally more sound by applying results obtained in recyclability and life cycle analyses.
Products, manufacturing process as well as logistics have been designed taking into account the
environmental aspects. Our environmental management system, certified to ISO 14001, is the
tool for carrying out our environmental policy.
These instructions are trendsetting and it is on the customer's responsibility to ensure that local
the legislation is followed.
10.2. Average material content

The material content (average percentage of the mass) which have been used in the manufacturing
the electrical machine is the following:
Fabricated steel frame synchronous machines (AMG and AMZ)

Steel 81 %
Copper 13 %
Cast iron 2%
Insulation materials 3%
Other 1%
10.3. Recycling of material required for transport

After receiving the machine into the site, the package and the transportation locking have to be
removed.
• The transportation locking is made of steel and can be recycled.
• The package is made of wood and can be burned.
• The sea trial package to some countries like Australia have special requirements, and is made
of impregnated wood that must be recycled according to local instructions.
• The plastic material around the machine can be recycled.
• The rust protection material covering the machined surfaces can be removed with petrolbased
solvent detergents and the cleaning rags are hazardous waste which have to be handled
according to the local instructions.
10.4. Recycling of the complete machine
10.4.1. Dismantling of the machine

Because of the weight of the components, the person who does the dismantling has to have adequate
skills to handle heavy components to prevent dangerous situations.
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10.4.2. Frame, bearing housing, covers and fan

These parts are made of structural steel, which can be recycled according to local instructions.
All the auxiliary equipment, cabling as well as bearings have to be removed before melting the
material.
10.4.3. Components with electrical insulation

The stator and the rotor are the main components, which include electrical insulation materials.
There are, however, auxiliary components which are constructed of similar materials and which
are hence dealt with in the same manner. This includes various insulators used in the terminal
box, exciter, voltage and current transformers, power cables, instrumentation wires, surge arrestors
and capacitors. Some of these components are used only in synchronous machines and some are
used only in very limited number of machines.
All these components are in an inert stage once the manufacturing of the machine has been
completed. Some components, in particular the stator and the rotor, contain a considerable amount
of copper which can be separated in a proper heat treatment process where the organic binder
materials of the electrical insulation are gasified. To ensure a proper burning of the fumes the
oven shall include a suitable after burning unit. The following conditions are recommended for
the heat treatment and for the after burning to minimize the emissions from the process:
Heat treatment
Temperature: 380…420 °C (716…788 °F)
Duration: After receiving 90 % of the target temperature the object shall stay a
minimum of five hours at this temperature
After burning of the binder fumes

Temperature: 850…920 °C (1562…1688 °F)
Flow rate: The binder fumes shall stay a minimum of three seconds in the burning
chamber
NOTE: The emission consists mainly of O2-, CO-, CO2-, NOx-, CxHy-gases and
microscopic particles. It is on the user's responsibility to ensure that the process
complies with the local legislation.
NOTE: The heat treatment process and the maintenance of the heat treatment
equipment require special care in order to avoid any risk for fire hazards or
explosions. Due to various installations used for the purpose it is not possible
for ABB Oy to give detailed instructions of the heat treatment process or the
maintenance of the heat treatment equipment and these aspects must be taken
care by the customer.
10.4.4. Permanent magnets

If the permanent magnet synchronous machine is melted down as a whole, nothing needs to be
done to the permanent magnets.
If the machine is dismantled for more thorough recycling and if the rotor must be transported after
it, it is recommended that the permanent magnets are demagnetized. The demagnetization is done
by heating the rotor in the oven until the permanent magnets reach a temperature of 300 °C (572
°F).

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Section 6 - Manual
NOTE: Magnetic stray fields, caused by an open or disassembled permanent magnet

synchronous machine or by a separate rotor of such a machine, may disturb
or damage other electrical or electromagnetic equipment and components,
such as cardiac pacemakers, credit cards and equivalent.
10.4.5. Hazardous waste

The oil from the lubrication system is a hazardous waste and has to be handled according to local
instructions.
10.4.6. Landfill waste

All insulation material can be handled as a landfill waste.

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AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13

ABB ref. 1637HH101-111
7.
Accessory
Information
ABB
164/616

AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13

ABB ref. 1637HH101-111
Contents
Accessory Information
Delivered with Machine
ZRD 6 and ZRC 6 ............................................1
Control Valve - SVDN ......................................4
Pliotron CR Air Filter ........................................5
Current Transformer T4 KSG ...........................7
Current Transformer T3 KSG .........................13
Current Transformer T2 KSG .........................17
Voltage Transformer T1 .................................21
Varistor Module SXV 40K550 C .....................25
Anti-condensation Heater RER 1 ...................27
Resistance Temperature Detector - PYR_L ..30
Resistance Temperature Detector - PYR_A ..34
Silicon Diode LND SD600N20PC ..................36
General Instructions for Lubrication Units

Used with Electrical Motor Bearings ..............37
Bearing Documentation by RENK
Unitrol 1020 User's Manual
Unitrol 1020 System Description
Other Documentation
ABB
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Section 7 - Accessory Information
ZRD 6 and ZRC 6
Brush ZRD 6
Purpose
Brush for shaft grounding.
NOTE: Grounding brush is a wearing part.
Requirements
• Size: 1.25” x 0.75” x 3.25”
• Resistivity: 0.83µΩ/m
• Hardness: 25 Shore Scleroscope
• Density: 3.54g/cm3
• Flexural strength: 23 N/mm2
• Material: Metal graphite
• Voltage drop: Low
• Friction coef.: Low
Order Related Information

Stock unit: pcs
Order unit: pcs
Weight per unit: 0.1 kg
ZRD 6 and ZRC 6 - 1

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0.63
0.312 [15.88]
[7.92]
45°
0.500
[12.70]
3.250 ± 0.032 3.125
[82.6 ± 0.8] [79.38]
Ø 0.323 THRU
2x Ø 0.640 0.219
5.50 +- 0.38
0.00
139.7 +- 9.7
0.1
-
1.250 - 0.007
0.011
-
31.8 - 0.2
0.3
4X CHAMFER 0.093 X45°
-
0.750 - 0.007
0.011
-
19.1 - 0.2
0.3
ZRD 6 and ZRC 6 - 2

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Brush holder ZRC6
Purpose
Holder for shaft grounding brush (ZRD 6).
Requirements
Material: Brass
Order Related Information

Stock unit: pcs
Order unit: pcs
ZRD 6 and ZRC 6 - 3

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Control Valve - SVDN
Use
Flood adjustment for flood lubricated sleeve bearings
Marking
ZLS SVDNa
a = DN number
Specification
Nominal pressure: PN 16
Max. working pressure: 1,6 MPa (1600 kPa, 16 Bar)
Material: brass
Surface treatment: nickel-plated
Code Type DN A B C [mm] D [mm] E F [mm] W e i g h t

[mm] [kg]
68067308 Z L S 10 G3/8 18 57 75 G3/8 ~33 0.155
SVDN10
70002922 Z L S 15 G1/2 20 65 85 G1/2 ~37 0.21
SVDN15
70002931 Z L S 20 G3/4 25 81 106 G3/4 ~45 0.49
SVDN20
Control Valve - SVDN - 4

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Pliotron CR Air Filter
Purpose
Pliotron CR Air Filters are designed to remove atmospheric dust including sub-visible particles
down to the particle range of 10 microns and less. Sub-visible particles are the predominant cause
of extended surface soilage as well as dirt generated electrical circuitry failure.
Description
The Pliotron CR (Commercial/Residential) is a permanent, self charging, electrostatic panel air
filter. It is contructed of washable, woven polyethylene fibre and incorporates a non-woven,
synthetic fibre mat, both of which are enclosed in a rust resistant, galvanized steel frame and
reinforced by 0.5’’ mesh galvanized steel hardware cloth. The filter can withstand temperatures
up to 100ºC (212ºF). The polyethylene media is chemically inert to the majority of contaminants
encountered in ventilation systems.
Principle of Operation
Polyethylene, a high-dielectric plastic, has an inherent capability to generate both positive and
negative surface charges in close proximity. Residual surface charges are always present on
polyethylene, and combined with the frictional forces of an air stream substantially increases the
voltage of these charges. As no external electrical energy is required, polyethylene can be
considered as self charging.
As airborne dust particles are of either positive or negative charge, they are both attracted and
retained by the opposite charges on the filter media. This electro-static arresting greatly enhances
the normal mechanical action of the filter.
Maintenance
The filter should be cleaned on an established regular basis to obtain maximum efficiency ensuring
longer life and long term low running costs.
Pliotron CR Air Filter - 5

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The filter may be cleaned either by simply using a vacuum, firstly on the upstream side, then
repeated on the discharge side. This will assist in maintaining peak performance. Periodically (to
be established and maintained) a thorough flush through with clean water, either by immersion
or with a fine spray in the opposite direction to the air flow. If contaminated by oily or greasy
substances, a detergent solution should be used, after which the filter must be rinsed with clean
water.
Marking
WJFA a x b x c
a = width (mm)
b = length (mm)
c = thickness (mm)
(e.g. WJFA 500 x 725 x 24)
Specification
Code Net face Pressure Airflow Net area of A B

velocity loss Pa m3/s filter m2
m/s
88319206 3 98 0.300 0.10 245 500
10209072 3 98 0.600 0.20 375 625
88157001 3 98 0.511 0.17 400 500
88319605 3 98 0.631 0.21 400 625
10209510 3 98 0.811 0.27 425 725
10209013 3 98 0.811 0.27 500 625
10208181 3 98 0.961 0.32 500 725
Order related information

Airfilter PLIOTRON CR, Width (a) x Length (b) x Thickness (c). This factory standard must be
attached to the order.
Stock unit: pcs
Order unit pcs
Designation
CR
Pliotron CR Air Filter - 6

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Current Transformer T4 KSG
Use
Differential protection for generator
Marking
KSG a b/c d/ef
a = type
b = rated primary current 1 [A]
c = rated primary current 2 [A]
d = rated secondary current 1 [A]
e = rated secondary current 2 [A]
f = specified requirements
M = marine
1 = two protection cores
2 = measuring and protection cores
Specification
Indoor service
Standard: IEC 60044-1
Insulation level: 17.5/38/95 kV
Primary terminal marking: P1, P2
Secondary terminal marking: 1S1, 1S2 and 2S1, 2S2
Rated thermal current: Ext. = 120%
Short-time withstand current Ith 1s at least 50 * Ipn
Operating temperature range: -30 °C ... +60 °C
Operating frequency: 50/60 Hz
Peak withstand current Idyn: 2.5 * Ith
Max. allowed width: 170 mm
Max. allowed height: 240 mm
Max. allowed length: 415 mm
Vibration withstandability: Sine vibration, IEC 60068-2-6; test Fc (same as EN and BS EN
60068-2-6); frequency range 10 … 100 Hz V = 30 mm/s rms (42 mm/s 0-peak); frequency 100
… 300 Hz a = 18.8 m/s² (26.6 m/s² 0-peak)
Dimension according to enclosed drawing
Current Transformer T4 KSG - 7

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Tightening of terminal screw: M5/M6 3.2/3.3 Nm, M12 63 ± 7 Nm
General Specification
Secondary current: 1 or 5 A
Core 1, accuracy and burden: 5P10, 20 VA
ABB Marine Application

Secondary current: 1 A
Core 1, accuracy and burden: 5P25, 5 VA or optionally 0.5 Fs 10, 20 VA
Requirements, type D and C
Primary Primary
Weight approx.
current Ipn current Ipn Code Marking
[kg]
[A] [A]
75 150 9909241 KSG D 75/150 1/1 24
75 150 9909242 KSG D 75/150 5/5 24
100 200 9909243 KSG D 100/200 1/1 24
100 200 9909244 KSG D 100/200 5/5 24
125 250 9909247 KSG D 125/250 1/1 24
125 250 9909248 KSG D 125/250 5/5 24
300 600 9909249 KSG D 300/600 1/1 24
300 600 9909250 KSG D 300/600 5/5 24
400 800 9909251 KSG D 400/800 1/1 24
400 800 9909252 KSG D 400/800 5/5 24
500 1000 9909253 KSG D 500/1000 1/1 24
500 1000 9909254 KSG D 500/1000 5/5 24
1250 9909255 KSG C 1250 1/1 30
1250 9909256 KSG C 1250 5/5 30
1500 9909257 KSG C 1500 1/1 30
1500 9909258 KSG C 1500 5/5 30
2000 9909259 KSG C 2000 1/1 30
2000 9909260 KSG C 2000 5/5 30
75 150 9910997 KSG D 75/150 1/1M1 24
75 150 9910998 KSG D 75/150 1/1M2 24
100 200 9910999 KSG D 100/200 1/1M1 24
100 200 9911000 KSG D 100/200 1/1M2 24
125 250 9911002 KSG D 125/250 1/1M1 24
125 250 9911003 KSG D 125/250 1/1M2 24

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Primary Primary
Weight approx.
[kg]
[A] [A]
300 600 9911004 KSG D 300/600 1/1M1 24
300 600 9911005 KSG D 300/600 1/1M2 24
400 800 9911006 KSG D 400/800 1/1M1 24
400 800 9911007 KSG D 400/800 1/1M2 24
500 1000 9911008 KSG D 500/1000 1/1M1 24
500 1000 9911009 KSG D 500/1000 1/1M2 24
1250 9911010 KSG C 1250 1/1M1 30
1250 9911011 KSG C 1250 1/1M2 30
1500 9911012 KSG C 1500 1/1M1 30
1500 9911013 KSG C 1500 1/1M2 30
2000 9911014 KSG C 2000 1/1M1 30
2000 9911015 KSG C 2000 1/1M2 30
Requirements, type I and R
Primary Primary
Weight approx.
[kg]
[A] [A]
75 150 9877332 KSG I 75/150 1/1 24
75 150 9877333 KSG I 75/150 5/5 24
100 200 9877334 KSG I 100/200 1/1 24
100 200 9877335 KSG I 100/200 5/5 24
125 250 9877336 KSG I 125/250 1/1 24
125 250 9877337 KSG I 125/250 5/5 24
250 9877342 KSG R 250 1/1 26.5
300 600 9877344 KSG R 300/600 1/1 26.5
300 600 9877345 KSG I 300/600 5/5 24
400 800 9877346 KSG I 400/800 1/1 24
400 800 9877347 KSG I 400/800 5/5 24
500 1000 9877348 KSG R 500/1000 1/1 26.5
500 1000 9877349 KSG I 500/1000 5/5 24
1250 9877356 KSG R 1250 1/1 26.5
1250 9877357 KSG I 1250 5/5 24
1500 9877358 KSG R 1500 1/1 26.5
1500 9877359 KSG R 1500 5/5 26.5
2000 9877360 KSG R 2000 1/1 26.5

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Primary Primary
Weight approx.
[kg]
[A] [A]
2000 9877361 KSG R 2000 5/5 26.5
Dimension
Dimensiondrawings ofcurrent
drawings of current transformers
transformers
Type D
Dimension drawings of current transformers

Type D
A=355 B=245 C=192
A=355 B=245 C=192
Type C
Figure 4-1 Type D
Type C
Figure 4-2 Type C

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Figure 4-3 Type R

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Figure 4-4 Type I

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Use
Excitation power during generator short circuit.
Marking
KSG a b
a = type
b = rated primary current [A]
Specification
Insulation level: 0.72 / 3 kV
Terminal marking: P1, S1, S2
Short-time withstand current Ith 1s: 60 * Ipn
Window: 70 mm
Screw of secondary terminal: M5 / 2.5 Nm
Fixing screw: M8 / 8 Nm
60068-2-6); frequency range 10 …100 Hz V = 30 mm/s rms (42 mm/s 0-peak); frequency 100
… 300 Hz a = 18.8 m/s² (26.6 m/s² 0-peak)
Requirements
STANDARD SELECTION OF T3 CURRENT TRANSFORMERS
Table 5-1. Transformers used in connection with excitation current limiter, Accuracy class PX
Code Type of designation Primary Sec. cur- Knee Excitation Max knee Inner Height Weight
current rent Isn point current Ie point resist- [mm] approx.
Ipn [A] [A] voltage Ek at Ek [A] voltage Ek ance Rct [kg]
at 50 Hz at 60 Hz at 20 °C
at least [V] [Ω]
[V]
9909222 KSG KOKM 1EF 150 150 4.5 50 0.44 72 0.08 160 14
9909227 KSG KOKM 1EF 200 200 5 65 0.42 94 0.08 160 12
9909229 KSG KOKM 1EF 250 250 5.5 70 0.35 102 0.08 160 11

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Code Type of designation Primary Sec. cur- Knee Excitation Max knee Inner Height Weight
current rent Isn point current Ie point resist- [mm] approx.
Ipn [A] [A] voltage Ek at Ek [A] voltage Ek ance Rct [kg]
at 50 Hz at 60 Hz at 20 °C
at least [V] [Ω]
[V]
9909230 KSG KOKM 1EF 300 300 6 74 0.32 107 0.09 160 10
9909231 KSG KOKM 1EF 400 400 6.5 74 0.3 107 0.09 160 10
9909232 KSG KOKM 1EF 500 500 7 85 0.25 119 0.2 160 10
9909233 KSG KOKM 1EF 600 600 7 95 0.2 133 0.2 140 8
9909234 KSG KOKM 1EF 800 800 7 95 0.15 133 0.3 120 5
9909235 KSG KOKM 1EF 1000 1000 7.5 105 0.15 142 0.3 120 5
9909236 KSG KOKM 1EF 1250 1250 7.5 110 0.15 143 0.4 120 4
9909237 KSG KOKM 1EF 1500 1500 8 110 0.15 143 0.4 120 4
9909238 KSG KOKM 1EF 2000 2000 8.5 110 0.15 143 0.4 120 4
Table 5-2. Transformers used in connection with excitation current limiter
Code Type of designation Primary Sec. cur- Max. bur- Knee Flux dens- Inner Height Weight
current rent Isn den at 50 point ity at resist- [mm] approx.
Ipn [A] [A] Hz Sn voltage knee ance [Ω] [kg]
[VA] (50 Hz) point
[V] voltage
[T]
9874469 KSG IFJ-3 100 100 4 80 38 1.5 0.05 160 18
9874474 KSG IFJ-3 125 125 4.3 100 43 1.5 0.05 160 16
9874475 KSG IFJ-3 150 150 4.5 105 50 1.5 0.08 160 14
9874476 KSG IFJ-3 200 200 5 150 60 1.5 0.08 160 12
9874477 KSG IFJ-3 250 250 5.5 190 70 1.5 0.08 160 11
9874478 KSG IFJ-3 300 300 6 230 76 1.5 0.09 160 10
9874479 KSG IFJ-3 400 400 6.5 230 68 1.5 0.08 125 6
9874480 KSG IFJ-3 500 500 7 285 80 1.5 0.2 125 6
9874481 KSG IFJ-3 600 600 7 340 95 1.5 0.2 125 5
9874482 KSG IFJ-3 800 800 7 315 90 1.5 0.3 125 5
9874483 KSG IFJ-3 1000 1000 7.5 390 105 1.5 0.3 125 5
9874484 KSG IFJ-3 1250 1250 7.5 425 115 1.5 0.4 125 4
9874485 KSG IFJ-3 1500 1500 8 515 125 1.5 0.4 125 4

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Code Type of designation Primary Sec. cur- Max. bur- Knee Flux dens- Inner Height Weight
current rent Isn den at 50 point ity at resist- [mm] approx.
Ipn [A] [A] Hz Sn voltage knee ance [Ω] [kg]
[VA] (50 Hz) point
[V] voltage
[T]
9874486 KSG IFJ-3 2000 2000 8.5 685 150 1.5 0.4 125 4
Accuracy of T3 - ct's Class 3 10P2.5 Fs 3.4

In other words i.e.
• saturation max 10 % at current 2.5 * Ipn
• saturation min 10 % at 3.4 *Ipn

• accuracy class 3 i.e. max error 3% at 0.5 * Ipn
Type KOKM 1EF
Figure 5-1 Type KOKM 1EF

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Type IFJ-3 Section 7 - Accessory Information
Figure 5-2 Type IFJ-3

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Use
Normal use for current sensing for AVR.
Marking
KSG Ipn T2
Ipn = primary current (A)
Refer to the Technical Specification in section 3 for correct Type Designation Code.
Specification
Insulation level: 0.72 / 3 kV
Terminal marking: P1, P2, S1, S2
Frequency: 50 - 60 Hz
Primary currents, see table: Ipn
Short-time withstand current Ith 1s: 60 * Ipn
Secondary current: Isn = 1 A
Accuracy class: 0.5
Burden, see table
Window: 70 mm
Screw of terminal cover: M4 / 1.0 Nm
Screw of secondary terminal: M5 / 2.5 Nm
Fixing screw: M8 / 8.0 Nm
Weight approximately: 2.5 kg
60068-2-6); frequency range 10 …100 Hz V = 30 mm/s rms (42 mm/s 0-peak); frequency 100
… 300 Hz a = 18.8 m/s² (26.6 m/s² 0-peak)

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Code Type Primary current A Rated burden VA

9872221 KSG 0100T2 100 3
9872222 KSG 0125T2 125 4
9872223 KSG 0150T2 150 4
9872224 KSG 0200T2 150 4
9872225 KSG 0250T2 250 5
9872226 KSG 0300T2 300 5
9872227 KSG 0400T2 400 5
9872228 KSG 0500T2 500 5
9872229 KSG 0600T2 600 5
9872230 KSG 0800T2 800 5
9872231 KSG 1000T2 1000 5
9872232 KSG 1250T2 1250 5
9872233 KSG 1500T2 1500 5
9872234 KSG 2000T2 2000 5

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Figure 6-1 Type KOKM 1EC6

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Type IFJ-2
Figure 6-2 Type IFJ-2

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Voltage Transformer T1
For spares ordering, provide the following information
• Machine serial number and work number
• Details of requested scope
• Copy of transformer rating plate
• Delivery quantities and detail
Technical requirements of primary winding
Voltage UnV, FnHz

Connection Y
Terminal marking A, B, C
Test voltage ( winding to case ) ( 2 x Un + 3 kV ) x 1.15 / 50Hz / 1 min
• Air insulation gap 30 mm
• Cables:
- plastic insulated cable MVJ1,5 4 kV (Nokia) diameter 7 mm, free length 2.5 m
- additional silicon insulation, when U < 11.5 kV, diameter 13 mm
- additional silicon insulation, when U > 11.5 kV, diameter 17 mm
Technical requirements of the first secondary winding
Voltage U1V
Output S1 = 3.2 kVA Continuously 5.5 kVA 2 min
Connection yn0
Terminal marking a, b, c
Test voltage 2.5 kV / 50 Hz / 1 min
Secondary to be protected with circuit breaker
Voltage Transformer T1 - 21
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Cable:
• XLPE insulated cable LM-HF 0,6/1(1,2) kV (TEMA) 5x1.5 (Max. conductor temperature
+90°C, Halogen free according to IEC 60754-1 and -2); diameter 10.8 mm; free length 3.7 m
Technical requirements of the second secondary winding
Voltage U2V
Output S2=300 VA
Accuracy CL 1.0 or CL 0.5, 10 VA when S1 < 1200 VA
Connection yn0
Terminal marking 2a, 2b, 2c

Cable:
Technical requirements of the third secondary winding
NOTE: The third secondary winding only as option
Voltage U2V
Output S3=300 VA continuously
Accuracy CL 1.0 or CL 0.5, 10 VA when S1 < 1200 VA
Connection yn0
Terminal marking 3a, 3b, 3c
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Cable:
Environmental limits
Vibration amplitude 0 - peak 0.8 mm, when f ≤ 8 Hz

Vibration speed 30 mm / s, when 8 < f < 100 Hz
Vibration acceleration 2.5 g, when f ≥ 100 Hz
Vibration shock 5g
Operating temperature 0 – 60°C
Storage temperature -30°C - +75°C
Humidity 95 % / +40°C
Additional data
Protection class IP – 00
Temperature rise class B
Losses 250 W
Voltage rations Un / U1 / U2, fn
Connection Yyn0yn0
Contact markings A, B, C, a, b, c, 2a, 2b, 2c
Weight per unit 78 kg
188/616

Type designation
KSG3PUa/b c d
a = Primary winding (V)
b = Secondary 1 Winding (V)
c = Frequency (Hz)
d = Number of secondary
189/616

Varistor Module SXV 40K550 C
Marking:
SXV 40K550 C
Specification:
Varistor Type LS40K550QPK2

Marking VRMS 550 V, VDC 745V,Imax
(8/20) µs 40000 A
Manufacturer Siemens
Capacitor Type MKP
Marking 0,1 µF +-10%600Vac, 1000
Vdc
Manufacturer Fischer & Tausche
Box Type SKB 33
Manufacturer Semikron Oy
Teflon FEP insulated cable Type 25303 – 14/19 VA 1,941 mm2
length 250 mm - 1000 mm
Manufacturer Teflontalo Irpala Oy
Further information:
• Varistor module and capacitor in parallel
• Polarity does not matter
• Can be connected between + and – poles in both directions
• Connection diagram shall be fixed on the module
Order related information:
Design unit pcs

Order unit pcs
Weight per unit 0.18 kg
Use
For rotating rectifier of a synchronous machine.
Varistor Module SXV 40K550 C - 25

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Varistor Module SXV 40K550 C - 26

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Anti-condensation Heater RER 1
Marking
RER 1-a/b
(a = nominal power, b = nominal voltage).
Use
As a standstill heating element for AM_ synchronous machines.
Code Type N o m i n a l Power [W] N o m i n a l Voltage [V]

power [W] voltage[V]
9871212 RER 1 - 800 720-870 115 110-120
800W/115V
9871213 RER 1 - 800 700-900 235 220-250
800W/235V
9871214 RER 1 - 800 720-970 400 380-440
800W/400V
9871215 RER 1 - 800 760-840 490 480-500
800W/490V
Technical requirements
1. Material of the tubular heating element: AISI 304.
2. Material of the attachment ear: AISI 304.
3. Operating temperature of the connection cables: 100° C.
4. Operating voltage of the connection cables: 500 V.
5. Cross section area of the connection cables: 1.0 - 2.0 mm2.
6. Connection of the connection cables with a connecting clamp: 6.3.
7. Halogenous free connection cables.
8. Test voltage: 1500 VAC.
Further Information
Information stamped on the tube of the heating element: Manufacturer, power, voltage,
manufacturing number, month and year of manufacture.

Stock unit: pcs
Order unit: pcs
Anti-condensation Heater RER 1 - 27

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FLAT CONNECTOR 6,3

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Resistance Temperature Detector - PYR_L_/_
Marking
PYR abLcd/ef
a = resistance material
b = resistance [Ω] at 0 °C
L = slot type sensor
c = length of sensor [code]
d = length of cable [m]
e = wires (pcs)
f = armouring (X), shielded (Z), either (empty)
EX = Ex-approved (Ex e)
EXI = Ex-approved (Ex ia)
_A = class A (if empty, class B)
e.g. PYR PT100LG4/4EX
Specification
Standard IEC 60751 class {see table}
Requirements
Dielectric strength min. {see table} kV (50 or 60 Hz) for 1 minute
ATEX and IECEx approved for zone 1 and zone 21
Withstand of VPI (Vacuum Pressure Impregnation) process
Exposure to +180 °C temperature
Cases which have shielded cable: space around the shield needs to be filled with elastomer
Sensors from new suppliers must always be tested by ABB to confirm withstand of VPI process
Further Information
PFTE insulated flexible Cu-wires 0.25 mm2 (AWG#23), not twisted (flat cable 2 x 5 mm) or
twisted {see table} contained in a common PFTE jacket
Maximum thickness of the cable {see table} mm
Usable temperature: -60 °C … +180 °C (safe area), -50 °C … +180 °C (Ex)
Not necessarily halogen free
Cable length tolerance: <7000 mm: L1 = L1 ± 75 mm ; ≥7000 mm: L1 = L1 + 4 % … -0 %
ABB will perform for each detector a withstand voltage test (1500V AC, 50 Hz for 1 minute) to
the machine frame acc. to IEC 60034-1
Resistance Temperature Detector -

PYR_L_/_ - 30
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Measuring current and self-heating: sensor must meet the requirements of IEC 60751 clause 6.4.3
with 1 mA measuring current
Maximum current withstand for sensors with resistance 10-120 Ω at 0 °C: Sensor must withstand
50 mA of DC current for 1 min at 20 °C without suffering any damage or changes in the measured
value compared before and after the current loading test.
Maximum current withstand for sensors with resistance 1000 Ω at 0 °C: Sensor must withstand
10 mA of DC current for 1 min at 20 °C without suffering any damage or changes in the measured
value compared before and after the current loading test
Standardized articles
ABB item ABB BU article Type designation Class Dielec- Twis- Ø L1 L2 L3 Ex ap- Ex ap-
code code tric ted [mm] [mm] [mm] proved proved
strength wire [Ex ia II [Ex e II
[kV] C] T4]
9872265 3AAM700006-1 PYR PT1000LC3/4 B 5 No 2 3000 50 - - -
60136041 3AAM700006-2 PYR PT100LC3/4EX B 5 No 2 3000 50 - - x
60175195 3AAM700006-3 PYR PT100LG4/4EX B 5 No 2 4000 200 - - x
9875204 3AAM700006-4 PYR PT100LG4/4ZEX B 3.2 Yes 3 4000 200 140 - x
9882634 3AAM700006-5 PYR PT100LG6/4EX B 5 No 2 6000 200 - - x
9882635 3AAM700006-6 PYR PT100LG6/4ZEX B 3.2 Yes 3 6000 200 140 - x
9872555 3AAM700006-7 PYR PT120LG4/4 B 5 No 2 4000 200 - - -
9872546 3AAM700006-8 PYR PT1000LG4/4 B 5 No 2 4000 200 - - -
9872557 3AAM700006-9 PYR CU10LG4/4 B 5 No 2 4000 200 - - -
9872556 3AAM700006-10 PYR NI120LG4/4 B 5 No 2 4000 200 - - -
60042012 3AAM700006-11 PYR PT100LG10/3 B 3.2 Yes 2.8 10000 200 - - -
9877756 3AAM700006-12 PYR PT100LG7/3Z B 3.2 Yes 2.8 7000 200 140 - -
9870614 3AAM700006-13 PYR PT100LG10/3EX B 3.2 Yes 2.8 10000 200 - - x
9086424 3AAM700006-32 PYR PT100LG10/3EXI B 3.2 Yes 2.8 10000 200 - x -
9878029 3AAM700006-15 PYR PT100LG18/3ZA B 3.2 Yes 2.8 18000 200 1440 - -
9887863 3AAM700006-16 PYR PT100LG6/4ZAEX B 3.2 Yes 3 6000 200 545 - x
9888019 3AAM700006-17 PYR PT100LC3/4EX_A A 5 No 2 3000 50 - - x
9890367 3AAM700006-18 PYR PT100LG4/4EX_A A 5 No 2 4000 200 - - x
9890710 3AAM700006-19 PYR PT100LG4/4ZEX_A A 3.2 Yes 3 4000 200 140 - x
9890711 3AAM700006-20 PYR PT100LG6/4EX_A A 5 No 2 6000 200 - - x
N/A 3AAM700006-21 PYR PT100LG6/4ZEX_A A 3.2 Yes 3 6000 200 140 - x
9883557 3AAM700006-22 PYR PT100LC3/4ZEX B 3.2 Yes 3 3000 50 140 - x
N/A 3AAM700006-24 PYR PT100LC6/4EX B 5 No 2 6000 50 - - x
N/A 3AAM700006-25 PYR PT100LC6/4EX_A A 5 No 2 6000 50 - - x
9872008 3AAM700006-26 PYR PT100LG18/3 B 3.2 Yes 2.8 18000 200 - - -
9024198 3AAM700006-28 PYR PT100LC9/4EX B 5 No 2 9000 50 - - x
PYR_L_/_ - 31
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ABB item ABB BU article Type designation Class Dielec- Twis- Ø L1 L2 L3 Ex ap- Ex ap-
code code tric ted [mm] [mm] [mm] proved proved
strength wire [Ex ia II [Ex e II
[kV] C] T4]
9024210 3AAM700006-29 PYR PT100LC9/4EX_A A 5 No 2 9000 50 - - x
9024500 3AAM700006-30 PYR PT100LC9/4ZEX B 5 No 2 9000 50 - - x
9024515 3AAM700006-31 PYR PT100LC9/ZEX_A A 5 No 2 9000 50 - - x
Use
To be fitted in stator slot of form wound stators for measuring the temperature of windings. Voltage
area U = 15 kV. Sensor with length 50 mm is not suitable for NEMA machines.

MDF code: 4BE
Order unit: pcs
L1 L2±3
100
13 CONNECTION +0.5
7 -0.25
+0.5
CABLES, PFTE JACKET 2 -0.25
UNINSULATED MAX 6
Ex-LABEL
(CERTIFICATE NUMBER
AND CERTIFIED AREA)
Figure 10-1 Sensor with cable without armouring
L1 L2±3
100 PFTE JACKET
13 CONNECTION WITH SHIELD,
Ø FREE +0.5
7 -0.25
+0.5
CABLES, CABLE TWISTED 2 -0.25
UNINSULATED
SHIELD
WITHOUT INSULATION
2:1
L3
5...10 10...15 5...15
A MIN 10 B C D E
Figure 10-2 Sensor with shielded cable
A PTFE shrinkable sleeving

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B The strands of the screening are bent on top of the cable. This is important in order to prevent
the sharp strand ends from puncturing the wire insulation
C In this part under the sleeving A the individual wires need not to be parallel (but it is allowed)
D In this part the individual wires need to be parallel (not twisted) in order to make this part
thin enough (max. 2 mm). No shrinkable sleeving in this part.
E The end of the sleeving (if used, not compulsory) on top of the actual element must stop
here

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Resistance Temperature Detector - PYR_A_/_
Use
To be fitted in the shell of sleeve bearings for measuring the temperature of the bearing
Description
The detector is manufactured to the standard specification IEC 751 class B.
Marking
PYR abcAde/fg
a = number of the detectors
1 = 1 detector
2 = 2 detectors
b = resistance material
PT = platinum
c = resistance [Ω] at 0°C
A = rapid connector probe
d = length of sensor [code]
e = length of cable [m]
f = wires (pcs)
g = armouring (X), shielded (Z), either (empty)
e.g. PYR PT100AG7/4Z
Refer to the Technical Specification in Section 3 for correct Type Designation Code.
Requirements
Dielectric strength min 1 kV (50 or 60 Hz) for 1 minute
Degree of protection IP68
EMC shield must not touch mechanically the protective tube (electrically insulated)
Order Information
Stock unit : pcs
Order unit : pcs
Weight per unit : approximately 200 g
Further Information
PTFE insulated flexible Cu-wires 0.25 mm2 (AWG#24) contained in a common EMC shield and
PTFE insulation
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Not halogen free

Variable insertion lenght (L1)
Usable temperature: -60°C … +180°C
Measuring current max 10 mA
Code Type designation L1 [mm] Weight [g]

9877130 PYR PT100AG7/4Z 200 200
9877134 PYR PT100AJ7/4Z 300 215
9877135 PYR PT100AL7/4Z 400 230

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Silicon Diode LND SD600N20PC
Specification
IF(AV) = 600 A, when TC= 92 °C
VRRM = 2000 V
Direction of circuit : cathode to stud
Thread size : 3/4” x 16 UNF-2A
General Information
Tightening torque : 35...40 Nm (threads lubricated)
Order Information
Approximate weight per unit: 0.454 kg
Silicon Diode LND SD600N20PC - 36

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General Instructions for Lubrication Units Used with Electrical Motor

Bearings
This instruction is not project-specific. Numerical values, drawings and flow diagrams related to
a particular project can be found in the technical specification, main dimensions drawing and the
oil lubrication unit drawings. These documents are located in the User’s Manual (Chapters 3 and
4).
This instruction is valid for lubrication units used with synchronous machine sleeve or roller
bearings.
13.1. Safety instructions for oil lubrication
13.1.1. General safety instructions

The pipes convey pressurized fluid which may reach extremely high temperatures – up to over
+60 degrees Celsius. Pipe, hose or joint breakages, and the resulting oil discharges, may cause
hazardous situations that lead to severe accidents.
13.1.2. Health hazards

Bearing oils and some additives may irritate the skin, cause an allergic reaction or oil acne upon
repeated skin contact. In addition, when inhaled oil mist may cause respiratory irritation, headache
and nausea. Oil mist spreading into the working area, or oil spilling on platforms intended for
walking increases the risk of slipping. The noise level of the machinery can be high, which is why
ear protection is recommended in the vicinity of running systems.
13.1.3. Burn hazard

The oil temperature may rise above +60 degrees Celsius. Oil this hot can cause burn injuries.
13.1.4. Fire hazard

When mixed with dust, oil spilled onto the floor or machine bodies is a severe fire hazard.
13.1.5. Oil jet hazard

Pressurized hoses or similar components must not be handled with bare hands as a high-pressure
fluid leak can penetrate the skin. Eye protection must be worn when working in the proximity of
running systems.
13.1.6. Hose impact hazard

A bent hose, when pressurized, tends to straighten, while an uncoiled hose begins to convulse
due to the reacting force of the discharging fluid. The hoses are the weakest points of the system.
Outdated hoses must be replaced with new ones sufficiently early on.
General Instructions for Lubrication

Units Used with Electrical Motor
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13.1.7. Safety during maintenance and repair work

Installation, maintenance, and repair work relating to the system must always be assigned to a
professional hydraulics technician who is thoroughly familiar with the operation and structure of
the system. The performance of the work must be supervised. Staff working with oil lubrication
must be made aware of the special requirements of the work, such as cleanliness.
Maintenance and repair work must primarily be conducted when the system is depressurized. A
running system can only be serviced to the extent that it has been designed to be serviced while
operational.
When commencing maintenance and repair work that require the system to be depressurized,
ensure that the lubrication targets have come to a stop before shutting down the pumps.
Once the pumps have been deactivated, accidental start-up must be prevented by locking the
safety switches of the electric motors or, if none are available, by removing the motor fuses. A
plate indicating the person responsible for the procedure must always be placed on locked safety
switches and removed fuses. The safety locks may only be removed by the person who put them
in place.
Always use the appropriate tools and methods when performing maintenance and repair work.
Avoid spilling oil on the floor, and remove oil spillages without delay. Opened pipe and hose
joints must be fastened immediately after installation. Before finishing the work, all joints and
couplings of the system being serviced or repaired must be checked and, if necessary, tightened.
Before starting the pumps, ensure that no other maintenance work on the system is underway.
When activating the pumps, avoid being in the proximity of the repaired system components.
After repairs, inspect the system for leaks. Do not tighten leaking joints when they are pressurized.
13.2. Lubrication Unit Types
13.2.1. Bearing-specific lubrication unit

Lubrication units are needed for sleeve bearings when ring/disk lubrication of the bearing no
longer functions due to exceeding the admissible peripheral speed or when high friction losses
and/or heat transfer through the shaft requires external oil cooling. Furthermore, lubrication units
are needed in order to ensure the reliable functioning of the bearings at low rotational speeds.
In roller bearings, lubrication units are used for filtering the oil and transporting the losses from
the bearing.
When there is a lubrication unit, oil rings or oil disks should be regarded as being intended for
use in emergency situations where the oil feed from a lubrication unit has been disrupted for some
reason. However, in such a situation the operation time is limited. It should be noted that in such
a case oil rings serve as protection for the radial part only, not for the thrust bearings.
If there is no oil ring or disk, as in dry sump bearings, a secured second supply (stand-by pump
motor) is required. The stand-by motor must be driven by a source of energy which is independent
of the mains (e.g., emergency 3-phase current, DC, compressed air etc.).

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Figure 13-1 A typical bearing-specific lubrication unit
1. Motor and pump assembly
2. Flow switch
3. Oil in
4. Oil out
5. Pressure relief valve
6. Oil filter
7. Mechanical clogging indicator (red pin)
8. Electrical clogging indicator
9. Water in
10. Water cooler
11. Water out

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13.2.1.1. Hydraulic diagram of the bearing specific lubrication unit

The hydraulic diagram of a typical bearing specific lubrication unit is shown in the following
figure.
Figure 13-2 Hydraulic diagram of a typical bearing-specific lubrication unit
1. Oil in
2. Water out
3. Water in
4. Oil out
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5. OPTION: Visual Flow Meter
6. OPTION: Electronic Filter Indicator
7. OPTION: Standby motor
13.2.1.2. Main components of the bearing-specific lubrication unit

• Oil pumps
The lubrication unit is equipped with a gear pump driven by an induction motor. As an option,
a standby motor and pump assembly can be included in the unit. In the event of a failure of
the normal pump, the standby motor will be switched on within 2 seconds.
• Filtering unit
The oil filter of the lubrication unit is equipped with a filter housing and filter insert. The filter
has a mechanical visual indicator for detecting clogging of the filter insert. The visual indicator
is a red pin on top of the filter housing. The pin will come out when the filter insert is clogged
and replacement of the filter insert is needed. As an option, an electrical indicator can be added
on top of the filter housing. The mechanical clogging indicator (red pin) will be fully functional
also with the electrical indicator. The signal type of the electrical indicator is binary logic.
• Cooling unit
Normally, the lubrication unit is equipped with an oil-water or oil-air cooler which is installed
on the side of the lubrication reservoir. The oil temperature is controlled by a thermostat.
• Flow switch
All lubrication units are equipped with a flow switch. The oil flow is monitored by a flow
sensor. The flow switch gives an alarm when the oil flow drops to some 40 to 60% of the
rated flow. The flow switch includes a visual flow meter scale to manually check the flow
rate.
• Pressure relief valve

A pressure relief valve protects the lubrication unit for overpressure, and is factory-adjusted
to 9 bar.
• Pipe heater cable (optional)

The pipe heater cable is needed for low ambient temperatures. In case of mineral oils, the pipe
heater cable is needed, for instance, when the ambient temperature is below +4 degrees Celsius
when using ISO-VG 68 oil, below -2 degrees Celsius when using ISO-VG 46 oil, or below
-7 degrees Celsius when using ISO-VG 32 oil. Synthetic oil cases are to be calculated separately
according to the oil specifications. The heater cable is assembled around the inlet oil pipe and
pump to warm the inlet oil above the temperature limit value depending on the oil viscosity.
The voltage supply options are 110…120 or 208…277 Vac (with UL classification), or 110
or 230 Vac (without UL classification). The pipe heater is a self-adjustable unit: as regards
safety, there is no need to cut off the pipe heater voltage supply.

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13.2.2. Bearing specific jack-up unit (hydrostatic unit)

A jack-up unit is needed for:
• Feeding high pressure oil, in order to jack up the shaft when operating at low speed or during
rundown periods
• Prevent damage to the sliding surfaces of the sleeve bearings and shaft during a prolonged
slowdown time at a speed below the transitional speed (*
(* The number of revolutions, when hydrodynamic lubrication of metal-to-metal contact areas

begins; the transitional speed is calculated by the bearing manufacturer and can vary greatly
depending on the application. Typically, the range is from 50…150 rpm.
Figure 13-3 A typical bearing-specific jack-up unit
2. Oil in
3. Oil out
5. Pressure switch, decreasing, 6±1 bar
6. Oil filter

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7. Test coupling / ventilation (M16X2)
8. OPTION: electrical clogging indicator
9. Mechanical clogging indicator (red pin)
10. Pressure gauge
11. Flow restrictor valve
As jack-up units are intended to reduce the wear on the bearing shell white metal during start-up
and slow-turning, they are not immediately critical for safe operation. Thus, if a jack-up unit is
not operational, the situation needs to be corrected as soon as possible in order to reduce bearing
wear. A generator may be safely started, stopped and slow-turned temporarily even without jack-up
units. However, exceptions are variable speed drive (VSD) motors that may require constant
hydrostatics due to their low operational speed.
The high-pressure pumps for hydrostatic lifting units are constant volume pumps, i.e. they supply
a defined oil throughput. The oil pressure of the jack-up unit varies during the start-up of the
machine and while it is running. After the shaft begins to rotate, the pressure drops because the
hydrodynamic lubrication begins to work.
Figure 13-4 Oil pressure as a function of time
1. Starting peak
2. Constant pressure
3. Pressure drop
4. Shut-down
Hydrostatic oil pressure variation can be split into four main parts.

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1. Starting peak
The maximum load-bearing capacity of the system is determined by the maximum pump
pressure, which is usually limited to 200 bars. The maximum pump pressure occurs during
the starting process, due to the oil wedge being narrow when the bearing is still at rest. For
this reason, when the shaft begins to lift there is a remarkable pressure surge.
2. Constant pressure
As soon as the oil wedge becomes wider as the shaft is lifted further, the pressure decreases,
depending on the bearing geometry and the oil throughput, since the effective load-bearing
surface is increased. Then, the weight of the shaft and the high pressure feed reaches a certain
balanced state at which the pressure is around 80…100 bar.
3. Pressure drop
After the shaft begins to rotate, the pressure drops because the hydrodynamic lubrication
begins to work. As the speed increases and the shaft starts to fluctuate into its natural position,
the pressure continues to drop to as low as 10…30 bar.
4. Shut-down
The jack-up unit can be shut down when the speed of the shaft has increased to a value which
ensures reliable hydrodynamic lubrication in the bearing. In general, the jack-up unit should
be switched off not until the nominal speed of the machine is reached. Exceptions are variable
speed drive (VSD) motors that may require constant hydrostatics due to their low operational
speed. On VSD motors, the jack-up unit switch-off speed is defined in the technical
specification of the machine.

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13.2.2.1. Hydraulic diagram of the bearing-specific jack-up unit

The hydraulic diagram of a typical jack-up unit is shown in the following figure.
Figure 13-5 Hydraulic diagram of a typical bearing-specific jack-up unit
1. Oil out
2. Oil in
4. Filter assembly with mechanical clogging indicator, electrical indicator as an option
5. Test coupling / ventilation (M16X2)
6. Pressure gauge
7. Pressure switch, decreasing, 6±1 bar
8. Flow restrictor valve

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13.2.2.2. Main components of the bearing-specific jack-up unit

• Oil pumps
The jack-up unit is equipped with a gear pump driven by an induction motor.
• Filtering unit
The oil filter of the jack-up unit is equipped with a filter housing and filter cartridge. The filter
has a mechanical visual indicator for detecting clogging of the filter insert. The visual indicator
is a red pin on top of the filter housing. The pin will come out when the filter insert is clogged
and replacement of the filter insert is needed. As an option, an electrical indicator can be added
on top of the filter housing. The mechanical clogging indicator (red pin) will be fully functional
also with the electrical indicator. The signal type of the electrical indicator is binary logic.

A pressure relief valve protects the unit for overpressure, and this is factory-adjusted to 200
bar.
• Pressure switch
The pressure switch protects the unit by giving an alarm when the pressure of the unit falls
below the factory-adjusted value of 6 ± 1 bar (decreasing). When the pressure has first increased
above 6 ± 1 bar (e.g., to 90 bar) and then started to decrease and reached the set value of 6 ±
1 bar, the pressure switch will give an alarm signal. The signal type is binary logic.
If necessary, the pressure switch setting can be adjusted with the pressure switch wheel adjuster.
The adjustment value is read from the wheel adjuster scale.
• Pressure gauge
The pressure gauge shows the actual pressure in the unit.
• Pipe heater cable (optional)

The pipe heater cable is needed for low ambient temperatures. In case of mineral oils, the pipe
heater cable is needed, for instance, when the ambient temperature is below +19 degrees
Celsius when using ISO-VG 150 oil, below +7 degrees Celsius when using ISO-VG 68 oil,
below +1 degrees Celsius when using ISO-VG 46 oil, or below -4 degrees Celsius when using
ISO-VG 32 oil. Synthetic oil cases are to be calculated separately according to the oil
specifications. The heater cable is assembled around the inlet oil pipe and pump to warm the
inlet oil above the temperature limit value depending on the oil viscosity. The voltage supply
options are 110…120 or 208…277 Vac (with UL classification), or 110 or 230 Vac (without
UL classification). The pipe heater is a self-adjustable unit: as regards safety, there is no need
for cutting off the pipe heater voltage supply.
13.2.3. Lubrication and jack-up unit with reservoir

Lubrication and jack-up unit with reservoir is usually needed when high oil flow values for bearings
are required or the customer prefers a lubrication system as a single unit.

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Figure 13-6 A typical lubrication and jack-up unit with reservoir. Control and monitoring
components are wired to a terminal box.
1. Hydrostatic jack-up oil out
2. Hydrostatic jack-up oil out
3. Terminal box
4. Oil filters
5. Pressure switches
6. Lubrication oil out
7. Lubrication oil out
8. Water in
9. Water out
10. Oil in
11. Flow gauges
12. Oil filling

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Lubrication units vary in detail depending on requirements. All pumps may be fitted with a standby
unit, and lubrication may include lubrication of axial surfaces. See project specific drawing details
of the unit in the particular project. In some arrangements, such as in the connection of a dry sump
bearing lubrication unit, the pumps and reservoirs can be mounted separately onto an
instrumentation panel including oil filters, heat exchangers, flow monitoring and controlling.
13.2.3.1. Hydraulic diagram of the unit with a reservoir

The hydraulic diagram of a typical unit with a reservoir is shown in the following figure.
Figure 13-7 Hydraulic diagram of a typical lubrication and jack-up unit with reservoir
1. Lubrication oil
2. Hydrostatic jacking
3. Water out
4. Water in
5. Water out 45°C
6. 35°C, water in 10 l/min
7. alarm 9 l/min
8. alarm 2.3 l/min
9. Decreasing 6±1 bar

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10. Ventilation screw
11. Air bleed
12. V=200L Oil ISO VG68
13. Pipe end 50mm from the bottom of reservoir
14. Pipe end 10mm from the bottom of reservoir
15. Emptying ball valve
13.2.3.2. Main components of the unit with a reservoir

• Lubrication oil reservoir
The lubrication oil reservoir is made of steel or stainless steel (option), including an integrated
dip tray under the reservoir. The oil reservoir volume is dimensioned for more than 5 times
the rated oil flow per minute.
• Oil pumps
In nearly every case, the unit is equipped with gear pumps driven by an induction motor.
Normally, these pumps are installed vertically onto the oil reservoir. In some cases, there may
be two optional oil pumps feeding oil into the unit. In general, the main pump unit, which
ensures the oil supply during normal operation, is supplied with electrical power from the
network. As a standby, if a failure occurs in the oil feeding circuit, a second pump will be
switched on within 2 seconds.
• Filtering unit
The filtering unit of the unit is normally equipped with twin filters that are monitored by
pressure sensors. On the pump side of the filters, there is a three-way valve that can be used
for manual switching from one filter to another.
• Cooling unit
Normally, the unit is equipped with an oil-water or oil-air cooler which is installed on the side
of the lubrication reservoir. The oil temperature is controlled by a thermostat.
• Flow measuring unit

All lubrication units are equipped with a flow gauge including an electrical sensor. The oil
flow is monitored by a flow sensor. The flow sensor gives an alarm when the oil flow drops
to some 40…60% of the rated flow. The inductive sensor in the flow meter is not adjusted to
the rated figure but to 40…60% flow. In some cases, the oil flow may be split into several
feeding lines that are all equipped with their own flow gauges.
• Oil heater
An oil heater is needed to preheat and maintain the oil temperature at the correct level in the
reservoir, before starting the actual feeding. The oil heater is controlled with a thermostat
which protects the oil from overheating.

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A pressure relief valve protects the unit from overpressure, and is factory-adjusted to a set
value given in the hydraulic diagram.
• Pressure switch
The pressure switch protects the unit by giving an alarm when the pressure of the unit falls
below the factory-adjusted value of 6 ± 1 bar (decreasing). When the pressure has first increased
above 6 ± 1 bar (e.g., to 90 bar) and then started to decrease and reached the set value of 6 ±
1 bar, the pressure switch will give an alarm signal. The signal type is binary logic.
If necessary, the pressure switch setting can be adjusted with the pressure switch wheel adjuster.
The adjustment value is read from the wheel adjuster scale.
• Other typical components

Some other components that may be included in the unit such as
- Pressure transducer
- Temperature thermostat for PT-100 (for the monitoring of oil temperature) in case of oil
heater
- Level watch
- Electrical oil level indicator
- Water-in-oil detector (usually only for central lubrication systems)
- Continuous flow measuring, output 4…20 mA (local display)
13.2.4. Return-oil unit with reservoir

In systems where the lubrication oil is taken from the diesel engine, the oil is normally returned
via a sloped oil return pipe. If the bearing is used in an environment where it has to withstand
larger inclinations i.e. marine conditions (e.g. an oil rig engine room), the oil return must be
secured with an oil pump in order to prevent flooding of the generator bearings.
With a zero inclination (or any inclination towards the engine) the return oil flows freely to the
engine oil sump by the main pipe. Oil level switch is at "stop".
If the inclination angle prevents oil from flowing by gravity, the oil level in the tank goes up. This
triggers a switch to "start" and automation should power up the return pumps. The pumps are
connected to a separate pressure pipeline. The pumps should be on until the oil level switch again
shows "stop". A separate pipeline is needed to avoid pumping oil from one tank to another, so
the pressure pipe has to be separate from the return pipe.
If the oil level rises too high (e.g. the oil pipe is blocked), the switch goes to "alarm". The
automation system should give an alarm on this at minimum.
The piping is not supplied by ABB. Two non-return valves should be fitted to the piping to prevent
oil flowing back from the engine to the generator (or from D-bearing to N-bearing) when the
inclination is towards the generator.
Instead of returning the oil to the engine, the generator can also be fitted with bearing-specific
lubrication units that cool and return the oil to the bearing.
The following figure shows the main components of a return-oil unit. The unit is typically
bearing-specific and fitted below the bearing.

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Figure 13-8 Return-oil unit with reservoir
1. Air filter
2. Oil level controller
3. Reservoir
4. Oil out
5. Oil in

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13.2.4.1. Hydraulic diagram of the return-oil unit with reservoir

The hydraulic diagram of a typical return-oil unit with reservoir is shown in the following figure.
Figure 13-9 Hydraulic diagram of a typical return-oil unit with reservoir
1. Oil in
2. Oil pressure
3. Oil out
4. Alarm 60 l
5. Start 45 l
6. Stop 25 l
13.2.4.2. Main components of the return-oil unit with a reservoir

• Oil reservoir
The oil reservoir is made of steel or stainless steel (option).
• Oil pumps
In nearly every case, the unit is equipped with a gear pump driven by an induction motor.

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A pressure relief valve protects the unit from overpressure, and is factory-adjusted to the set
value given in the hydraulic diagram.
• Oil level controller

The oil level controller monitors the oil level in the reservoir. The controller is equipped with
alarm, start and stop oil level limits according to the hydraulic diagram. With the oil level
controller, the return of the lubrication oil back to, e.g. the engine oil reservoir, is ensured
even in the marine conditions with varying inclinations of the ship. The oil returning pump
motor is started when the oil level reaches a certain oil level, and stopped when the oil level
has fallen to a certain level. The alarm level indicates problems in the return-oil unit operation.
• Air Filter
The air filter is needed in the reservoir for breathing and to prevent pressure fluctuations inside
the lubrication system.
13.3. Commissioning instructions
13.3.1. Flushing pipework

If the lubrication unit is bolted to the machine end shield or pedestal bearing support and includes
a finished pipework circuit, flushing is not needed as it has already been done at the ABB factory.
Make sure that the hoses/pipes are clean and that there are no defects in them.
If the lubrication unit and jack-up units are installed apart from the bearing and, thus, new pipework
is needed for assembly at site, the hydraulic pipework must always be flushed before
commissioning.
Note that the pipework at the side must follow ABB instructions for pipework. Special care needs
to be taken with the return pipes. The return oil pipe diameter should be as it is at the exit from
the bearing. The pipes needs to be installed in decline of 250…300 mm for each metre’s distance
from the bearings in addition to a worst inclination requirement in order to guarantee trouble-free
oil circulation. The oil pipes should be located so that they do not obstruct service and maintenance,
and supported so that they do not apply stress to the pipe flanges on the synchronous machine.
The return oil container should be constructed in such a way that no pressure can enter the oil
return piping from the container towards the bearing. This can be achieved, e.g. by placing oil
return pipe entrance to the container below oil surface. Non-return valves need to be installed in
case of return-oil systems with separate pumps as described in the previous chapter.
An auxiliary flushing unit (not included in ABB delivery) is recommended to be used for flushing.
To do this, an extra flushing filter must be fitted in the return line before the unit. Monitor the
indicator showing the filter condition and replace the filter insert when an alarm is given. Continue
flushing until the filter alarm switches off, around 2…3 hours after the cleaning or replacement
of the filter insert. An oil flow rate of 8…10 m/s is recommended for flushing. The temperature
of the flushing oil should be +40…+50 degrees Celsius. The oil used in flushing must be the same
as defined in the main dimensions drawing. The principle drawing of the auxiliary flushing unit
with the hydraulic diagram is shown in the following figure.

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Figure 13-10 Principle drawing of the auxiliary flushing unit with a hydraulic diagram
1. AUXILIARY FLUSHING UNIT
2. LUBRICATION UNIT
3. BEARING
4. Filter
5. Motor
6. Pump
7. Oil reservoir
8. Oil inlet
9. Oil outlet

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10. Connecting hoses for flushing
11. Connecting hose for flushing
If no external flushing device is available, flushing can be carried out with the lubrication unit's
own pump. To do this, an extra flushing filter must be fitted in the return line before the unit.
Monitor the indicator showing filter condition and replace the filter insert when an alarm is given.
Continue flushing until the filter inserts are no longer clogged, 2…3 hours after the cleaning or
replacement of the filter insert. The temperature of the flushing oil should be +40…+50 degrees
Celsius.
Before flushing, use hoses to connect the pipework sections to suitable flushing circuits. Bearings
are not permitted in this circuit.
Cutting burrs and weld slag must be removed at the flushing installation stage, and the pipes must
be thoroughly cleaned before installation. The return piping is cleaned by sand blasting. Pressure
piping is cleaned with clean-out plugs, compressed air or by pulling a rag through the pipe with
a cable wire.
Pipework must not be commissioned until its cleanness has been verified, e.g. with a particle
counter. The most common purity class for bearing lubrication units according to ISO 4406 is
16/13.
13.3.2. Before machine start-up

Make sure that the system is flushed as instructed. Use a particle counter or similar device so as
to verify this.
Make sure that the inside of the reservoir is clean. Fill the system with oil by using a filter pump.
NOTE: Make sure that the right type of oil is used. If the wrong type of oil is used,
this may lead to a bearing failure.
An insulation test is recommended for electric motors before commissioning.
Check the electric connections of the motor for the correct direction of rotation (test with a short
start). The correct direction of rotation is indicated on the electric motors and pumps with an
arrow.
Make sure that
• The operating and control voltages correspond to the rated value
• The inlet and output faucets are open
• The connections used for flushing have been removed and the connectors re-tightened
• The connections have been made according to the hydraulic diagram
Start the pumps and make sure that they start pumping oil. If a pump does not pump oil, stop and
re-start it a couple of times. If this does not help, fill the pump's output and inlet pipes with oil
and restart the pump. If even this does not help, perform bleeding via the bleeding valve, pressure
measuring nipple or pipe connection.
NOTE: Check from the data sheet of the pumps if pre-filling is required before start-up.
In the case of external oil supply, check the correct supply pressure. The oil
supply pressure manometer reading should be 125 ± 25 kPa (18 ± 4 psi).

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13.3.3. Operation and monitoring of the lubrication units

The lubrication unit must be started at least five (5) seconds before the start-up of the machine
and kept running until the machine has been shut down. A typical arrangement in automation is
to initiate the start-up procedure including start-up of the lubrication units, wait for couple of
second to see that there is no alarm signal due to pump-motor start up failure or too low a flow,
and then continue with start-up. If a stand-by pump motor system exists, this system must be
tested with the same arrangements before the main lubrication system.
The oil flow is monitored by a flow sensor. The flow sensor gives an alarm when the oil flow
drops to some 40…60% of the rated flow. The inductive sensor in the flow meter is not adjusted
to the rated figure but to 40…60% flow.
Check the oil flow from the oil flow meter.
The pressure switches and pressure relief valves are adjusted at the factory to the values indicated
in the hydraulic diagram.
Thermostat settings must always be checked during commissioning. Note that oil with too low a
temperature will not flow properly due to too high a viscosity.
13.3.4. Operation and monitoring of the jack-up units

The jack-up unit must be started up at least five (5) seconds before the start-up or shut-down
process start of the machine, when the speed of rotation is below the speed indicated in the technical
specifications (VSD motors), or when slow turning the machine. The typical arrangement in
automation is to initiate a start-up procedure including start-up of jack-up units, wait for a couple
of seconds to see that there is no alarm signal due to pump motor start-up failure or too low a
pressure, and then continue with start-up. If a stand-by pump motor system exists, this system
must be tested with the same arrangements before the main jack-up system.
The operation of the jack-up unit needs to be controlled by engine control or the frequency
converter and pressure switch. The oil pressure fluctuates depending on the rotational speed of
the shaft line, as described in the chapter on “Bearing specific lubrication unit”. The control using
pressure switches in the circuit should be performed using the following logic:
A) Start-up
When the jack-up unit is started and the pressure of the unit has increased above 6 ± 1 bar, the
pressure switch’s internal change-over switch will change its position. That can be used as an
indication for the normal operation of the unit. If the pressure after that decreases below 6 ± 1
bar, then the pressure switch will give an alarm.
B) Shaft line is rotating
When the machine has reached its nominal speed or a speed well above the transitional speed,
the jack-up unit should be switched off.
On VSD motor units, when the shaft line has rotated above a certain limit speed for more than
the specified time (normally 2…3 minutes) the frequency converter should shut down the pump.
It is not beneficial to run the jack-up unit during normal operations above the transitional speed.
The main purpose of hydrostatic jacking is to prevent damage to the sliding surfaces of the sleeve
bearings and shaft during rotation at speed below the transitional speed. “Transitional speed”
means the number of revolutions, when the hydrodynamic lubrication of metal-to-metal contact
areas begins. In order to ensure the maximum lifetime of the bearings, the above-mentioned limit
speed should be set as follows: transitional speed + 15 rpm. The transitional speed is calculated
by the bearing manufacturer and can vary greatly, depending on the application.

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NOTE: The settings of the limiting speed for shutting down the pump are highly
dependent on the application. These values must be checked from the technical
specification and the oil lubrication unit drawings. Such documents can be
found in the user's manual.
13.4. General maintenance instructions

The oil in a hydraulic system transmits energy and serves as a lubricant. Therefore, it is essential
for correct operation and the durability of the system that the oil is clean and of the correct grade.
Studies show that typically 70% of system malfunctions are due to dirty, low-quality or unsuitable
oil. For these reasons, hydraulic systems must always be equipped with a filter. Cleanliness is of
the utmost importance at every stage. No open containers of cotton waste should be in the vicinity
when servicing the machine or handling oil.
13.4.1. Regular Service
13.4.1.1. Daily checks

• When a process monitoring system is used, checks can be carried out weekly. Otherwise, the
following items should be checked daily:
• Oil level
• Oil temperature
• Filter condition indicator
• Replacement of filter inserts, when necessary
• Checking components and pipework for leaks and repairs when necessary
• Operating noise (are there any changes in the running sound)
• Visual inspection of hoses (abrasions, cracking, etc.)
• Surface temperature of actuators and components using a surface thermometer

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13.4.1.2. After 500 hours of operation (1st maintenance)

The following items should be checked after 500 hours of operation:
• Replace the filter inserts if necessary
• Check the pipe and component fastening and tighten if necessary
• Check the oil quality visually, or determine its purity with a particle counter ,or send a sample
to the oil company laboratory for analysis
• Top up with oil of the same grade if necessary
• If necessary, change the oil
• Check the electrical components and their wiring
• Clean the outside of the hydraulic unit
13.4.1.3. After 4,000 hours of operation (L1 and L2 maintenances)

All hydraulic units must be serviced at least once a year, including those with only a few operating
hours
Annual servicing must be planned in advance. When planning the service operation, take account
of defects and malfunctions discovered during daily checks as well as the need for repairs and
replacement according to the service life of individual components.
The following items should be checked after 4,000 hours of operation:
• Change the oil
NOTE: For self-lubricated bearings (i.e. bearing specific-lubrication or jack-up

unit) cleaning intervals with oil changes of approximately 4,000
operating hours are recommended and approximately 20,000 operating
hours for bearings with an oil circulation systems (i.e. units with a
reservoir). Shorter oil change intervals may be necessary in case of
frequent start-ups, frequent changes in direction of rotation of the
machine, high oil temperatures or excessively high contamination due
to external influences.
• Clean the inside of the reservoir with care and check the paint finish
• Replace filter inserts
• Clean the water cooler and check its condition
13.4.1.4. Servicing the components

All defective components should be replaced.
Disassembly and cleaning of parts:
• Check the parts for wear and replace when necessary
• Always replace the seals and check valve centring springs and bearings when necessary

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Instructions
For Installation and Maintenance
Slide Bearings TYPE SC36
RH-SCZIW36-E Rev. 02 23.02.2006

224/616
Installation and Maintenance
RENK AKTIENGESELLSCHAFT
Werk Hannover
Weltausstellungsallee 21
D - 30539 Hannover
Telephone: (0511) 8601-0
Telefax: (0511) 8601-266
e-mail: renk_hannover@renk.de
http:\\www.renk.de
All rights reserved. Copy or reproduction without prior permission of RENK Aktiengesellschaft Hannover
prohibited.
2 RH-SCZIW36-E Rev. 02 23.02.2006 © RENK AG Werk Hannover

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SC TYPE
Contents:
Bearing Coding...........................................................................................................................................4
General Drawing Slide Bearing SC.............................................................................................................6
General Drawing Rigid Seal........................................................................................................................9
1 Considerations for Use...........................................................................................................................12

2 Safety Instructions ..................................................................................................................................13
3 Operating Instructions after Standstill .................................................................................................14
4 Maintenance Schedule ...........................................................................................................................15
5 Oil Change ...............................................................................................................................................16
6 Preparatory Works ..................................................................................................................................17
6.1 Tools and devices ..............................................................................................................................17
6.2 Use of lifting devices..........................................................................................................................17
6.3 Preparation for dismantling................................................................................................................20
6.4 Dismantling of the shaft seals ............................................................................................................20
6.4.1 Rigid seal (Type 20).....................................................................................................................20
6.5 Dismantling of the housing ................................................................................................................21
6.6 Removal of the top part of the shell...................................................................................................21
6.7 Removal of the bottom part of the shell ............................................................................................21
7 Cleaning and Checking of the Bearing .................................................................................................22
8 Assembly of the Bearing ........................................................................................................................23
8.1 Assembly of the bottom part of the bearing on foundations.............................................................23
8.2 Fitting in the bottom part of the shell.................................................................................................24
8.3 Fitting in the top part of the shell.......................................................................................................24
8.4 Assembly of the top part of the housing............................................................................................25
8.5 Alignment of the bearing....................................................................................................................26
8.6 Assembly of the shaft seals ...............................................................................................................27
8.6.1 Rigid seal (type 20) .....................................................................................................................27
8.6.2 Insulated Bearings ......................................................................................................................28
8.6.3 Assembly of the Flinger ..............................................................................................................29
10 Corrosion Protection for Longer Standstill Periods............................................................................31
11 Transport Protection...............................................................................................................................32
12 Glossary ...................................................................................................................................................33
© RENK AG Werk Hannover RH-SCZIW36-E Rev. 02 23.02.2006 3

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Bearing coding

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SC TYPE
Type Heat Dissipation Shape of Bore and Type of Thrust part Size - Diameter
Lubrication
SC- smooth Z - lubrication by oil circulation with C - plain cylindrical bore Q - without thrust part 36 D = 325
pedestal bearing external oil cooling without oil ring (non-locating bearing ) D = 340
K - plain white metal lined
with taper land faces
(integrated)
Shaft seals Type 20 - rigid seal (IP 44)

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General Drawing
Slide Bearing type SC

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230/616
1.
2.
3.
4.
5 Housing - top part
6. Shell - top part
7.
8. Housing - bottom part
9. Tap hole
10. Spherical surface
11.
12.
13.
14. Oil drain plug
15. Foot plate
16. Foot plate bore
17. Dowel pin
18.
19. Oil sight glass
20. Shaft seal
21. Oil outlet connection bore
22. Connection bore for thrust part temperature measurement
23. Oil inlet connection bore
24.
25.
26.
27. Shell - bottom part
28.
29.
30. Shell - taper pin
31. Shell - split line
32. Tap hole - shell top and bottom part
33. Bearing housing - taper pin
34. Bearing housing - split line bolt
35. Eye bolt
36. Bearing housing - split line bolt
37. Housing end cover
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SC TYPE
General Drawing
Rigid Seal

232/616
59
60
65
61 (2x)
62
64
63
233/616
59. Rigid seal - top part
60. Bolt
61. Split line bolt ( from Size 36 up with centering pin )
62. Groove
63. Rigid seal - bottom part
64. Punched number
65. Punched number

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SC TYPE
1 Considerations for Use
The instructions for installation and operation are addressed to qualified technical personnel ( fitters,
mechanic installers mechanic engineers ).
Read these instructions carefully before starting assembly.
Slide bearings of type SC are almost universally used in the engineering industry as non locating and
locating bearings. 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 point for
water 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 too before
starting assembly and operation of the slide bearings.
In the case of insulated bearings, the inside spherical housing surfaces are lined with a non-
conducting PTFE film which projects out in some places in order to avoid sparkovers. The positioning
pin in the housing which puts the bearing shell (4) in its location is coated with non-conducting plas-
tic. The shaft seals are made of non-conducting material or they are electrically separated from the
bearing housing by insulated liners (12) and insulated thread joints. The temperature monitoring in-
struments which are to be fitted by the user have to be insulated accordingly (e.g. by using insulating
protective pipes, plastic screw fittings, etc.). RENK Hannover works will offer solutions upon request.
Additional technical documentation with detailed information is supplied in case of special version /
design bearings. Please contact RENK Export or Domestic Department for supplementary information
on bearings. Please indicate the bearing coding and the full order 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 dangers for the bearing or installation.
Useful recommendations and additional information are framed.
SC..Q This is how chapters, instructions or recommendations are marked when referring to a single type or
size of a bearing.
Example: Slide bearing type SC without thrust pads ( non-locating bearing )
- Instruction follows.
• Beginning of an enumeration.
( ) This is how the different parts of a bearing as described in the general drawings( numbers )
are marked in the text.
− Use the enclosed check-list before starting assembly or operation. Copies available on request.

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SC TYPE
2 Safety Instructions
Danger!
The installation and maintenance of the slide bearings should be carried out by:
• persons nominated by the safety representative
• persons correspondingly trained and instructed
• persons with knowledge on appropiate 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 or disassembly of the bearing !
Warning of injury!
Do not grab such heavy bearing parts as the bearing housing during assembly or disas-
sembly works. This could result in bruising or injury to hands !
Attention!
All parts of a slide bearing consisting of top and bottom half such as the housing, shells, shafts are
marked by engraved numbers. Fit together only the parts with the same number.
Attention!
In case • the admissible bearing temperature exceeds 15 K
• inadmissible vibrations occur
• unusual noises or odours are noticed
• monitoring equipment triggers alarm
shut down the installation and inform the maintenance personnel in charge.
Attention!
Do not operate the bearing below the transition speed values indicated in the bearing calculation,
thus avoiding inadmissible operating conditions, which could lead to damage to the bearing.
Attention!
Please observe our leaflet Technical Information No. 85 which refers to various sealing compounds
for extended technical applications.

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3 Operating Instructions after Standstill
− Clean the external parts of the bearing. Dust and dirt impede the radiation of the heat.
− Check with the instructions for the use of the lubricating oil if an oil change is neces-
sary.Depending on the duration of the standstill an oil change is either prescribed or recom-
mended. Carry out the oil change as indicated in Chapter 5.
− Retighten the split line bolts (34), (36) by using the following torque values:
Bearing size 36
Torque (34) [Nm] 610
Torque (36) [Nm] 75
− Tighten the foot plate bolts by using the following torque values. The torque values depend on
• the used foot plate bolts
• the material the bearing housing is made of and the foundation
( see also the Technical Documentation of the Installation )
− Retighten the connection bores for oil in-and outlets, the thrust part oil supply bores (optional).
The necessary torque values depend on the used pipe joints.
− In case a thermo sensor or / and an oil sump thermometer are used:
− check if they are well fitted ( see also the manufacturer's instructions )
− Retighten all screw plugs in the connection bores (14), (18), (21), (22), (23), by using the necessary
torque values:
Screw plug threads G 1/2" G 3/4"
Torque [Nm] 40 60
SCZC. − Start operating the oil supply system and check its functioning ( see also the Technical Documen-
tation of the Installation ). The supplied oil quantity at the bearing oil inlet must correspond to the
values indicated in the EDP-calculations.
− Check the functioning of the temperature monitoring equipment.
The bearing is now ready to work.

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SC TYPE
4 Maintenance Schedule
Maintenance work Deadline
Exterior cleaning of the bearing every 100-1000 hours
Oil change Bearing in reversing operation every 5000 operating hours

Bearing in continous operation every 20.000 operating hours
( please observe also the indications for the use of the lubri-
cating oil )
Bearing inspection During prevention maintenance works for the installtion .

Immediately if:
• the bearing temperature exceeds 15 K over the indicated

value (see the EDP-calculations)
• unusual operating noises occur
• unusual changes of the lubricating oil become visible

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5 Oil Change
Risk of Pollution!
Observe the instructions for the use of the lubricating oil. The manufacturer can provide information
on waste oil disposal.
− Shut down the installation and secure it against unintended operation.

− Shut down the oil supply system.
− Take all necessary measures to collect the whole quantity of the lubricating oil.
Let off the lubricating oil in still warm condition. Impurities and residues will thus be scavanged. Go
ahead as follows:
SCZC. − Let off and collect the lubricating oil of the oil supply system.
− Unscrew the oil drain plug (14). Let off the lubricating oil of the bearing and collect it.
Attention!
In case the lubricating oil contains unusual residues or is visible changed, eliminate the causes. If
necessary, carry out inspection works.
− Tighten the oil drain plug (14) by using the following torque values:
Bearing size 36
Torque [Nm] 60
SCZC. − Clean the oil container.

− Fill up the oil supply system with lubricating oil. Use a lubricant with the viscosity indicated on the
type plate of the bearing.
− Start the oil supply system in order to fill up the bearing with lubricating oil.
The bearing is ready to work when the quatity of lubricating oil supplied at the bearing oil inlet corre-
sponds to the value indicated in the EDP-calculations.

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SC TYPE
6 Preparatory Works
6.1 Tools and devices

− Following tools and devices are necessary:
• Allan key set
• Wrenching key set
• Open-jawed spanner set
• Feeler gauge ( up 0,05 mm )
• Caliper gauge
• Emery paper, plain scraper
• Oil stone
• Lifting devices
• Permanent sealing compound
• Cleaned, not fibrous cloth
• Oil with the viscosity indicated ( see bearing coding )
• Detergents
• Liquid screw locking devices ( e.g. LOCTITE 242 )
• Liquid sealing compound and Teflon-tape
6.2 Use of lifting devices
Warning of injury!
Before transport or lifting check if the eye bolts are tight ! Insecure eyebolts could result
in bearing becoming loose.
Before moving the bearing by the eye bolts make sure that the screws at the split line are
tightened, otherwise the bottom half of the bearing could become detached.
Make sure that the threads of the eye bolts are not exposed to bending stress, otherwise
the bolts could break off.
Follow exactly the instructions for the use of the lifting equipment.

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− Use elevating devices for following assembly and transport works:
Transport/Assembly of: Use lifting devices for the following bearing sizes
Whole bearing unit 36
Top part of the housing 36
Bottom part of the housing 36
Bearing shells 36
− Following steps are to be observed before using lifting devices:
Whole bearing unit

− Check if the split line bolts are tight (34), (36):
Bearing size 36
Torque (36) [Nm] 75
− Check if the eye bolt°(35) is tight.

− Connect the lifting devices to the eye bolt (35).
Top part of the housing

− Check if the eye bolt°(35) is tight.
− Connect the lifting devices to the eye bolt (35).
Bottom part of the housing

− Screw two eye bolts (35) with suitable threads tight into the cross-placed opposite tapped
holes (9).
Bearing size 36
Tapped hole M 24
− Connect the lifting device to the eye bolts (35).
Bearing shells
− Screw two eye bolts or screw hooks with suitable threads tight into the tapped holes (32):
Bearing size 36
Tapped hole M 12

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SC TYPE
− Connect the lifting device to the eye bolts or to the screw hooks.

242/616
6.3 Preparation for dismantling
Attention!
Make sure that the working place is clean. Contamination and damages to the bearing, especially of
the running surfaces, influence negatively the bearing performance and lead to premature damage.
Attention!
Do not use any violence or force !
− Shut down the installation and ensure it against unintended operation.

− Shut down the oil supply system.
− Dismantle all thermo sensors from the connection bores (22).
− Take all necessary measures to collect the lubricating oil.
− Unscrew the oil drain plug (14) and collect the lubricating oil of the bearing.
Risk of pollution!
Observe the instructions for the use of the lubricating oil. The manufacturer can provide information
on waste oil disposal.
− Tighten the oil drain plug (14) by using the following torque value:
Bearing size 36
Torque [Nm] 60
− Inform yourself about the maintenance and inspection of the oil supply system ( see also the Te-
chical Documentation of the Oil Supply System ). Carry out all necessary maintenance and inspec-
tion works.
6.4 Dismantling of the shaft seals

− Dismantle both shaft seals of the bearing.
Proceed correspondingly to the seal type:
• Rigid seal (Type 20) Chapter 6.4.1
6.4.1 Rigid seal (Type 20)

Type 20
− Loosen the bolts of the top part.
− Take out the split line bolts.
− Loosen the dowel pins with the help of a M10 screw and corresponding plain washer, by screwing
into the pins and finally remove the pins.
− Screw an eye bolt M12 or a screw hook into the tap hole at the top part.
− Connect the lifting device to the eye bolts or to the screw hooks.
− Remove the bolts of the top part.
− Take away the top part carefully, in axial direction, from the housing.
− Loosen the bolts of the bottom part.
− Screw two eye bolts M12 or screw hooks into the tap hole of the bottom part.
− Further on proceed as in the case of the top part.
− Remove the gasket from the flange surface.
− Damaged gaskets must be renewed.

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SC TYPE
6.5 Dismantling of the housing

− Take away the taper pins (33) ( available from size 40 up )
− Unscrew the 8 split line bolts (34),(36) and lift the top part of the housing (5).
6.6 Removal of the top part of the shell

− Take away the taper pins (30) ( available from size 40 up )
− Unscrew both split line bolts (31) and lift the top half of the shell (6).
Attention!
Do not damage the thrust and radial running surfaces!
6.7 Removal of the bottom part of the shell
Attention!
Make sure that all bearings mounted on a shaft line are opened. Loosen the split line bolts of the
housings.
Attention!
Do not let the lifting device come in touch with the seal and running surfaces of the shaft.
− Lift the shaft up to the point where shaft and bottom part of the shell (27) do not touch each other
any more. Protect the shaft against unintended movement.
− Turn the bottom part of the shell (27) out of the bottom part of the housing (8) and lift it away from
the shaft.

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7 Cleaning and Checking of the Bearing
Attention!
Use only non-aggressive detergents, such as for instance:
• VALVOLINE 150.
• Alcaline cleaning compounds (pH-value 6 to 9, short reaction time).
Warning of injury!
Please observe the instructions for the use of the detergents.
Attention!
Never use cleaning wool or fibrous cloth. Rests of such materials left in the bearing could lead to ex-
cessive temperatures.
− Clean the following parts thoroughly, to remove all rests of preservatives:

• inside the top part of the housing (5)
• inside the bottom part of the housing (8)
• all bare parts of the top and bottom part of the housing (5), (8)
• top part of the shell (6)
• bottom part of the shell (27)
− Carry out a visual check of the wear condition of all bearing parts. The following graph provides
information on the parts that must be replaced in case of wear signs. The right evaluation of the
wear condition, especially of the running surfaces of the bearing shell, implies a lot of experience.
If in doubt, replace the worn parts with new ones.
Bearing part Wear condition Maintenance proceedings
Bearing shell scoring Bearing temperature before inspection:
not increased - no new shells

increased - new shells
white metal lining damaged new shell
bow wave ridges new shell
Shaft seal Baffles broken or damaged new shaft seal
In the case of insulated bearings, check if the PTFE film and other components (positioning pin and
non conducting sleeve of the seals are in perfect condition.

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SC TYPE
8 Assembly of the Bearing
Attention!
Remove all impurities or similar 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 device (e.g. LOCTITE 242) for all housing, split line and flange bolts.
8.1 Assembly of the bottom part of the bearing on foundations
Attention!
Make sure that all bearings installed on a shaft line are opened. To open them untighten the bolts of
the split line of the housing.
Attention!
Do not let the lifting device touch the running surfaces of the shaft.
− Lift the shaft high enough to get sufficient place for assembly. Make sure the shaft does not move.
− Adjust the bottom part of the housing on the foundation on site. (see also Technical Documenta-
tion for the Installation ).
Attention!
Make sure that the bottom part of the housing (8) lays on th foot plate (15). This is the only way to
avoid deflexion of the bearing.
− Twist suitable foot bolts loose into the bores (16) (about 4 turns ) to fix the bottom part of the bear-
ing safely into its place. Use 8.8 quality screws with high radial loads.
Bearing size 36
Bore for foot bores (16) [mm] 46
Suitable foot screw thread M 42

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8.2 Fitting in the bottom part of the shell

− Apply some lubricant on the spherical surface (10) in the bottom part of the housing (8) 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 part of theshell (27) on the running surface of the shaft. Screw the bottom part of
the shell (27) into the bottom part of the housing (8) with the split line surfaces of both parts in true
alignment.
If the shell does not get screwed in easily, readjust the bottom part of the housing.
SC..K Attention !
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 lies on the bottom part of the shell (27).
8.3 Fitting in the top part of the shell

− Apply some lubricant on the running surfaces of the shaft. Use the same type of lubricant as indi-
cated for bearing operation (see type plate).
− Check if the punched number on the bottom shell (28) corresponds with the number punched on
the top part of the shell (26).
− Place the top part of the shell (6) on the shaft; both punched numbers (26), (28) should be on one
side.
Attention!
A wrong placed shell could jam the shaft thus leading to the damage of both shaft and bearing.
SC..K Attention!
Place the top part of the shell carefully on the shaft. The thrust parts of the top part of the shell should
not be damaged.
− Put in the taper pins (30).

− Tighten up both split line bolts (31) by using following torque values:
Bearing size 36
Torque [Nm] 75
− Check the split line of the bearing shell by using a feeler gauge. The split line should be less than
0,05 mm wide. If the split line is wider than this, dismantle both top (6) and bottom (27) part of the
shell. Rework the split line surfaces of the top (6) and bottom (27) shell with an oil rubber.

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SC TYPE
8.4 Assembly of the top part of the housing

− Check the true alignment of the split lines of the shell (6),(27) and bottom°(8) part of the housing.
− Check if the marking signs (29) on the top and bottom part of the housing correspond.
− Clean the split line surfaces of the top and bottom part of the housing (5), (8).
− Apply sealing compound over the whole surface of the split line of the bottom part (8) of the hous-
ing.
Please observe the instructions for the use of sealing compound.
− Lower the top part of the housing (5) vertically on the bottom part of the housing (8). The marking
signs should be on the same side of the bearing.Lower down the top part of the housing (5) till the
split line of the housing is not visible any more.
− Hit slightly with a hammer the bottom part of the housing (8), thus ensuring the alignment of the
spherical seating.
− Insert the 8 split line bolts (34), (36). Tighten them crosswise by using the following torque values:
Bearing size 36
Torque (36) [Nm] 75

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8.5 Alignment of the bearing
Attention !
If both a non-locating and a locating bearing are to be mounted on a shaft line, both bearings must be
adjusted in turn. Start with adjustement of the locating bearing.
− Measure the distances (a,b,c,d) between shaft and lateral bores of the housing on both sides of
the bearing.
d
5
c a
8
b
Illustration 1: Alignment of the bearing
If the measured values differ by more than 0,4 mm on each bearing side, re-adjust the bearing:
− To do so always loose the bolts of the split line (34) of both bearings.
− Use lining plates for the height adjustement of the bottom part of the housing (8).
− After every measurement tighten up the split line bolts (34), (36) again.
After adjustement of both bearings,

− tighten up the foot plate bolts with the necessary torque.
The necessary torque values are depending on
• the used foot plate bolts
• the material of the housing and the anchoring in the foundation (see also the
Technical Documentation of the Installation).
− Check the alignment.
− Bore both pin holes into the dowel pin bores (17) and insert the positioning pins.

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SC TYPE
8.6 Assembly of the shaft seals

− Assemble both shaft seals of the bearing.
Proceed according to the used seal type.
Rigid seal (type 20) Chapter 8.6.1
Insulated bearing Chapter 8.6.2
Mounting of flingers Chapter 8.6.3
Type 20 8.6.1 Rigid seal (type 20)

− Check the correspondence of the punched numbers (64) and (65) on the bottom part (63) and top
part (59) of the rigid seal.
− Clean • the flange surfaces of the top part (59) and bottom part (63) of the rigid seal.
• the split line surfaces of the top part (59) and bottom part (63) of the rigid seal.
• the flange surfaces of the housing.
− Apply a uniform layer of sealing compound to the following parts
• the split line surface of the bottom part of the rigid seal.
• the flange surface of the top and bottom part of the rigid seal.
Please observe the instructions for the use of sealing compound.
Illustration 2 Application of sealing compound to the rigid seal

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− Before assembling fix a gasket at the housing flange; make sure that the joint is perpendiculary at
the top.
− Press slightly the bottom part of the rigid seal from below against the shaft and fix it by using bolts.
− Place the top part carefully on the bottom part and insert the dowel pins.
− Tighten the bolts of the split line with the torque indicated.
− Press slightly the rigid seal from below against the shaft.
− Adjust the rigid seal in such a way that the clearance "f" between shaft and rigid seal at both split
lines is the same and tighten the bolts with the following torque values.
5 59
f f
8 63
Illustration 3 Alignment of the rigid seal
− Tighten the bolts (60) by using the following torque values:
Bearing size 36
Torque [Nm] 10
Insu- 8.6.2 Insulated Bearings

lated Use an insulating gasket in the case of a rigid labyrinth seal (rigid metal baffles) and an insulated
bearings shell. Apply non-hardening sealing compound to both sides of the gasket. Use fastening bolts with
insulating sleeves in the case of insulated rigid seals. To reach a higher torque rate, insert a washer
between the insulating sleeve and the fastening bolt.

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SC TYPE
8.6.3 Assembly of the Flinger

Flinger
seals The flinger is supplied cut to approximate size. During assembly it should be wrapped around the
shaft and accurately cut to length to ensure a close butt joint. The ends have to be glued. Preferably
use a cyanacrylate glue ( instant glue ).
Pass the garter spring (1) round the shaft and, holding one end in each hand, twist one end a few
turns as if unscrewing. Place the ends together and screw up.
The flinger is held in place on the shaft by the garter spring.
Illustration 4 Assembly of the flinger

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9 Starting operation after Inspection

− Fit the thermo sensor for:
• temperature measurement of the radial part in the thermo bores (22)
− Retighten the screw plugs in the connection bores (14), (18), (21), (22), (23), by using the following
torque values:
Screw threads G 3/4"
Torque [Nm] 60
SCZ... − Retighten the connection bores for oil inlet and outlet and the bores for the thrust part oil supply
( optional ). The torque depends on the threaded joints used.
− Retighten the foot bolts by using the necessary torque. The torque value depends on:
• the foot bolts used
• the material the bearing housing and the foundation are made of (see also
the Technical Documentation of the Installation ).
− Carry out a visual check of the assembled bearing.
− Fill up the oil supply system with lubricant. Use the same type of lubricant as indicated on the type
plate.
− Start operating the oil supply system in order to fill up the bearing with lubricant.
− Check
• the way the oil supply system works ( see also the Technical Documentation of the Installation ).
The lubricant quantity at the bearing oil inlet must correspond to the values indicated in the EDP-
calculations.
• if the temperature monitoring equipment works.
Attention!
Make sure that the bearing is free of impurities.
− Use a lubricant with the viscosity indicated on the bearing type plate.
Attention!
• Not enough lubricant leads to temperature rises and thus to damages to the bearing.
• Too much lubricant leads to leakages.
The bearing is ready for operation.

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SC TYPE
− Supervise the bearing during the trial run ( 5-10 operating hours ).
Pay special attention to:
SCZ. • the way the oil supply system works ( necessary lubricant quantity, lubricant pressure before en-
tering the bearing )
• bearing temperature
• sliding noises of the shaft seals
• tightness
• occurence of inadmissible vibrations.
Attention!
If the bearing temperature exceeds the calculated value by more than 15 K ( see the EDP-bearing
calculations ) stop the installation immediately. Carry out an inspection of the bearing and find out the
causes.
10 Corrosion Protection for Longer Standstill Periods
If you want to protect the bearing mounted on an installation against corrosion proceed as follows:
− Dismantle the bearing (see Chapter 6).
− Clean the bearing (see Chapter 7).
− Paint or spray the top part (6), and the bottom part (27) of the shell and the shaft with Tectyl 511.
− Assemble the bearing (see Chapter 8).
− Close all connection bores with screw plugs.
− Seal the gaps between • shaft seal and housing
• shaft seal and shaft
by using a self-adhesive, permanent tape.
− Remove the top part of housing (5). Spray some anti-corrosive such as Tectyl 511 or VALVOLINE
into the bearing.
− Put a bag of dessicant ( silicate gel ) inside. The dessicant absorbs the humidity and prevents the
formation of condensation water inside the bearing.
In case the standstill period is longer than 1/2 year:

− Repeat the preservation procedures.
− Put a new bag of dessicant into the bearing.
In case the standstill period lasts more years:

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

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11 Transport Protection
In case of a machine equipped with slide bearing type SC:

− Carry out the corrosion protection as described in Chapter 10 and apply enough lubricant on the
running surfaces of the bearing.
− Pull the rotor against the sub-frame by using timbers placed across the shaft and press firmly into
the bearing.
Illustration 5 Transport protection

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SC TYPE
12 Glossary
Rigid seal The rigid 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 seal is built of 2 halves, flanged at the bearing housing.The blades that wipe out the
lubricant are arranged into two groups.The first two blades, lying inside keep back most of
the lubricant. Five further blades protect the bearing from outside.They prevent the lubricant
overflow and the penetration of impurities.The overflown lubricant is collected into a cham-
ber lying between the both groups of blades.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 shells into the
housing.The shells are placed upon two spherical surfaces. 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.

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Faulty Contact between Shaft and Bearing Surface (defective geometry)

A slide bearing application will be reliable only if the shaft (the load) is carried by an oil film generated in a wedge-
shaped gap between shaft and bearing surface (hydrodynamic function). The Minimum required oil film thickness
is always that thickness what prevents the surfaces of shaft and bearing from any contact. If smaller, the friction
rises and wear of bearing white metal lining happens (for normal this is always the case on first and last moments
of shaft rotations at start/stop - otherwise a slide bearings lifetime would be infinitive). The hydrodynamic oil film
thickness for the very most applications will be in range of 0.015 up to 0.035 mm. Small values can be assumed
for bearings operating on temperatures above 75 °C and/or self lubricated, whereas values above 0.25 mm are
typical for bearings fed with cooled oil from an external pump (for an individual application the conditions had been
calculated on machines design state probably).
With above mentioned values anyone understands that the accuracy of the interacting surfaces geometry, the
shape of the "oil-wedge" and roughness, is (one of) the most important key for a proper slide bearing operation.
They also should realise that such accuracy hardly can be verified with common on-site measuring tools. A
Micrometer-gauge might be suitable to measure with a (incorporated) misleading of 0.01 mm - however, the
spindle can not find whether the shaft shape is a true cylinder or in waves, or if the shape of oil wedge is bad
(faults in range of some few 1/100 of a mm). Instead of dealing with Microns experienced technicians are applying
the "Blue Print"-Method (also known as "Prussian-Ink-Method") to verify the contact conditions between shaft and
bearing surface.
Bearings inspected after run times normally will show an area of brighter reflection of the white metal (sometimes
it is of dark appearance) - the so called “running pattern". Wear conditions typically are indicated by a large and
bright shining running pattern. The running pattern often will "tell" you what was going on in the bearing before:
Faulty contact conditions like misalignment and/or defective geometry often will leave symptomatic patterns
Please be aware that "running patterns" may differ in shape and size from the respective "blue print" because the
result from common blue print procedure is not affected from misalignment or thermal influences, which may have
affected the shell in previous assembling and operation conditions.
Following we will show "blue prints" or "running pictures" of faulty contact conditions, with hints to the root causes
of defects (almost a hint for rectification). The shown defects are those, we were experiencing in the past as "most
common defects" for Journal Bearings of cylindrical shape – special/rare cases are not shown.
Correct Blue Print "edge-loaded" concave shaft convex shaft

Clearance and shape alignment or conical (concave shell) (convex shell)
in good conditions shaft (or shell-bore)
blue print width:

α ≈ 30° (max. 45°)
insuff. clearance "waves" "spotted"

Blue Print should be taken after each
treatment of shaft or bearing lining - and
before assembling a spare shell.
Overhauling the bearing surface by
manual scraping possibly results in a
"spotted" blue print. However, the blue
area should have Min. 85 % within the
above shown "correct blue print" size.
or worn lining shaft or bearg. scraped bearg.
RENK-file: LFL_01B_forABB-SF (Jul2007).DOC gesp.: 19.07.07 (HS - Ca.) © RENK AG 1997 – 2007 – all rights reserved
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
UNITROL® 1020 User Manual
Automatic Voltage Regulator
Compact voltage regulator for synchronous machines
up to 20 A exciter current
Product Release 6.3xx

DSP Control: 6.3xx
MCU Control: 6.3xx
CMT1000: 6.3xx
Document No. 3BHS335648 E82

Revision Status Rev. H
Date 03 / 2016
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
ABB reserves all rights to this document and to the information and
topics contained in it. This also applies to any possible claims to
copyright or patents. Forwarding and/or the duplicating of this document
without the express permission of ABB is forbidden.
This document has been prepared and checked with great care. If
however it still contains errors, please report them to ABB.
ii 3BHS335648 E82 UNITROL 1020 User Manual

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
Table of Contents
Table of Contents ............................................................................................................... iii
Terms and Abbreviations ................................................................................................. vii
Chapter 1 - Introduction .................................................................................................... 1

1.1 General .......................................................................................................................... 1
1.2 Field of Application ......................................................................................................... 1
1.3 Contents of this Manual.................................................................................................. 2
1.4 Intended Audience ......................................................................................................... 3
1.5 Manufacturer’s Address ................................................................................................. 3
Chapter 2 - Safety Instructions ......................................................................................... 5

2.1 General .......................................................................................................................... 5
2.2 Qualifications and Responsibilities ................................................................................. 5
2.2.1 Qualifications and Responsibilities ............................................................................................. 5
2.2.2 Consequences of Non-Compliance ............................................................................................ 5
2.3 Safety Concept .............................................................................................................. 6
2.3.1 General ....................................................................................................................................... 6
2.3.2 Safety Rules ................................................................................................................................ 6
2.3.3 Residual Danger Areas ............................................................................................................... 6
2.4 Safety Regulations ......................................................................................................... 8
2.4.1 Structure of Safety Instructions ................................................................................................... 8
2.5 Instructions for Emergency Situations ............................................................................ 9
2.5.1 Firefighting .................................................................................................................................. 9
2.5.2 First Aid Measures for Electrical Installations ............................................................................. 9
2.5.3 Pacemaker ................................................................................................................................10
2.6 Danger signs .................................................................................................................10
Chapter 3 - Device Overview ........................................................................................... 12

3.1 General .........................................................................................................................12
3.2 Description of the Excitation System .............................................................................12
3.3 Hardware ......................................................................................................................13
3.3.1 Connection Diagram .................................................................................................................13
3.3.2 Control Interfaces ......................................................................................................................14
3.3.3 Block Diagram ...........................................................................................................................21
3.3.4 Device Connectors....................................................................................................................22
3.3.5 Digital Inputs .............................................................................................................................25
3.3.6 Digital Outputs ..........................................................................................................................27
3.3.7 Analog Inputs ............................................................................................................................29
3.3.8 Analog Outputs .........................................................................................................................31
3.3.9 Communication Ports................................................................................................................33
3.4 Software ........................................................................................................................38
3.4.1 Operating Modes ......................................................................................................................39
3.4.2 Startup Functions ......................................................................................................................43
3.4.3 On-line Operation Functions .....................................................................................................51
3.4.4 Limiters and Monitor Functions .................................................................................................55
3.4.5 Miscellaneous Functions ..........................................................................................................70
UNITROL 1020 User Manual 3BHS335648 E82 iii

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
3.4.6 Modbus for Remote Access ..................................................................................................... 75
3.4.7 Access Levels .......................................................................................................................... 76
Chapter 4 - Installation and Storage .............................................................................. 79

4.1 General ........................................................................................................................ 79
4.2 Safety Regulations ....................................................................................................... 79
4.3 Unpacking .................................................................................................................... 79
4.4 Mechanical Installation ................................................................................................. 80
4.5 Electrical Installation .................................................................................................... 81
4.5.1 Digital and analog IO cabling 1020 .......................................................................................... 81
4.5.2 Inrush current of UNITROL 1020 ............................................................................................. 81
4.5.3 Extended operation lifetime with external capacitor ................................................................ 82
4.6 Storage ........................................................................................................................ 83
4.6.1 Storage Conditions ................................................................................................................... 83
4.6.2 Disposal.................................................................................................................................... 83
4.7 Recycling Instructions .................................................................................................. 84
4.7.1 Manual Disassembly ................................................................................................................ 84
4.7.2 Mechanical Shredding .............................................................................................................. 84
Chapter 5 - Commissioning ............................................................................................ 85

5.1 General ........................................................................................................................ 85
5.3 Setting Aids .................................................................................................................. 86
5.3.1 Setting Aids .............................................................................................................................. 86
5.4 Work carried out while Machine is at Standstill ............................................................. 93
5.5 Work carried out while Machine is running ................................................................... 93
5.5.1 No-load Tests (nominal speed, not synchronized) .................................................................. 93
5.5.2 Tests under Load ..................................................................................................................... 93
5.5.3 Synchronization ........................................................................................................................ 94
5.6 Concluding Work after Commissioning ......................................................................... 95
Chapter 6 - Operation ...................................................................................................... 97

6.1 General ........................................................................................................................ 97
6.3 Panel Operation ........................................................................................................... 98
6.3.1 Panel Start-up .......................................................................................................................... 98
6.3.2 Display elements ...................................................................................................................... 99
6.3.3 Keypad Operation .................................................................................................................... 99
6.3.4 Emergency Excitation OFF .................................................................................................... 100
6.3.5 Setpoint Adjustment ............................................................................................................... 100
6.3.6 Menu Structure ....................................................................................................................... 101
6.3.7 Setpoint Step .......................................................................................................................... 104
6.3.8 Save to EEPROM .................................................................................................................. 104
6.3.9 Limiters ................................................................................................................................... 105
6.3.10 Alarms and Fault Messages................................................................................................... 106
6.4 PC Software Tool ....................................................................................................... 107
6.4.1 General................................................................................................................................... 107
6.4.2 System Requirements for CMT1000 Release 6.300 ............................................................. 107
6.4.3 Installing CMT1000 Software ................................................................................................. 108
6.4.4 Starting with CMT1000 ........................................................................................................... 113
6.4.5 Menu Structure of CMT1000 .................................................................................................. 116
6.4.6 Setup Menu ............................................................................................................................ 132
6.4.7 Communication Menu ............................................................................................................ 153
iv 3BHS335648 E82 UNITROL 1020 User Manual

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
6.4.8 Tune Menu ..............................................................................................................................158
6.4.9 Help Menu ...............................................................................................................................162
6.4.10 Save Parameter File ...............................................................................................................163
6.5 Additional Tools ..........................................................................................................164
Chapter 7 - Preventive Maintenance ............................................................................ 165

7.1 General .......................................................................................................................165
7.2 Safety Regulations ......................................................................................................165
7.3 Standard Procedures for Maintenance ........................................................................165
Chapter 8 - Troubleshooting ......................................................................................... 167

8.1 General .......................................................................................................................167
8.2 Safety Regulations ......................................................................................................167
8.3 List of Possible Faults .................................................................................................167
8.4 Repair .........................................................................................................................170
8.5 Compatibility ...............................................................................................................170
Chapter 9 - Technical Data ............................................................................................ 171

9.1 General .......................................................................................................................171
9.1.1 Ordering Information ...............................................................................................................171
9.1.2 Electrical Data of AVR UN1020: .............................................................................................171
9.1.3 Environmental data of AVR UNITROL 1020: .........................................................................174
9.1.4 UL Certification .......................................................................................................................174
9.1.5 Reliability UNITROL 1020 .......................................................................................................174
9.1.6 Battery life time information ....................................................................................................175
9.1.7 Mechanical data ......................................................................................................................175
9.2 Settings Record for UNITROL 1020 ............................................................................176
9.3 Parameter Settings, Default Values ............................................................................177
Chapter 10 - Appendix ..................................................................................................... 178

10.1 Documentation References .........................................................................................178
UNITROL® 1020 User Manual 3BHS335648 E82 v

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
Terms and Abbreviations
AC Alternating Current
AIO Analog Input and Output
AUTO Automatic Voltage Regulation (Auto Mode)
AVR Automatic Voltage Regulator
Bat Battery
CAN Controller-area network
CB Circuit Breaker
MAIN Main Channel in double channel systems.
CT Current Transformer
DC Direct Current
DIO Digital Input and Output
ESD Electrostatic Discharge
ETH Ethernet Terminal
EXC Excitation
FCB Field Circuit Breaker
GEN Generator
GFR Ground Fault Relay (Rotor Ground Fault Protection)
HW Hardware
IGBT Insulated Gate Bipolar Transistor
MANUAL Field Current Regulation (Manual Mode)
MCU Microcontroller unit
PC Personal Computer
PCB Printed Circuit Board
PDF Portable Document Format
PE Protective Earth (Protective Ground)
PF Power Factor Mode
PPE Personal Protective Equipment
PS Power Supply
PSS Power System Stabilizer
PT Potential Transformer
PWM Pulse Width Modulation
Q Reactive Power
RDM Rotating Diode Monitoring
SW Software
UMAUX UM Auxiliary Input Measurement
VAR Reactive Power Mode
V/Hz Volt per Hertz (-Limiter)
VDC Voltage Droop Compensation
VM Voltage Matching
UNITROL 1020 User Manual 3BHS335648 E82 vii

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
Chapter 1 - Introduction
1.1 General
The User Manual provides detailed information on the

 safety instructions
 description of the product,
 installation,
 commissioning & operation,
 maintenance and troubleshooting
of the UNITROL 1020, including detailed descriptions of the functions and
the hardware of the device. Technical data is included as well.
1.2 Field of Application
This advanced-design automatic voltage regulator is used for the excitation

of indirectly excited synchronous machines and motors. The regulator can
also be switched over to function as a reactive power-, power factor- or field
current regulator.
Back-up Channel
Batt
.
SM = Synchronous Machine
E = Exciter
Optional:
- Power System Stabilizer (PSS)
- Synchronization unit
- Data Logger
SM E
- Event Recorder
UNITROL 1020 User Manual 3BHS335648 E82 1

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Chapter 1 - Introduction 
SM = Synchronous Machine
E = Exciter
PMG = Permanent Magnet Gen.
PMG
Generator or motor excitation with
PMG or external supply.
SM E
1.3 Contents of this Manual
Chapter 1 - Introduction describes the contents of the User Manual and

provides the manufacturer’s information.
Chapter 2 - Safety Instructions explains the safety instruction levels and
provides general instructions on safety, which need to be strictly observed.
Chapter 3 - Device Overview outlines the description of the device,
operation modes, hardware capabilities and software features.
Chapter 4 - Installation and Storage provides information on environmental
conditions to be maintained during transportation and storage, information
on disposal and recycling of materials.
Chapter 5 - Commissioning provides information on preparing the device
for commissioning.
Chapter 6 - Operation describes the instructions how to operate the device.
Chapter 7 - Preventive Maintenance contains the maintenance schedule
and step-by-step instructions for specific maintenance tasks to be carried
out by the customer.
Chapter 8 - Troubleshooting provides instructions on how to proceed when
encountering problems.
Chapter 9 - Technical Data describes the technical data from the device,
ordering number and parameter list.
2 3BHS335648 E82 UNITROL 1020 User Manual

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 Chapter 1 - Introduction
1.4 Intended Audience
The User Manual addresses the following target groups:

 Engineering
 Installation personnel
 Operators
 Maintenance and repair personnel
1.5 Manufacturer’s Address
If any questions arise, consult the local ABB representative or the

manufacturer:
IMPORTANT!
When calling ABB, please leave your name, department and phone
number. This will allow the responsible ABB representative to call back
without delay.
ABB Switzerland Ltd

Static Excitation Systems, Voltage Regulators
and Synchronizing Equipment
CH-5300 Turgi / Switzerland
Telephone: +41 58 589 24 86
Fax: +41 58 589 23 33
For general inquiries and product information e-mail us at:
pes@ch.abb.com
Internet: http://www.abb.com/unitrol
24 h – Hotline for urgent service inquiries: +41 844 845 845

Email contact for questions and UNITROL 1000 support:
unitrol1000.supportline@ch.abb.com

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
Chapter 2 - Safety Instructions
2.1 General
Chapter 2 - Safety Instructions includes the safety instructions that must

be followed during installation, operation and maintenance of the
excitation system. Please read all instructions carefully before operating
the device and keep this manual for future reference.
2.2 Qualifications and Responsibilities
2.2.1 Qualifications and Responsibilities
Personnel involved in installation work and commissioning of the

UNITROL 1020 must be familiar, specially instructed and informed
about the residual danger areas according to the regulations currently in
force.
Operating personnel are 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 firefighting.
It is the owner’s responsibility to ensure that each person involved in the
installation and commissioning of the UNITROL 1020 has received the
appropriate training or instructions and has thoroughly read and clearly
understood the safety instructions in this chapter.
2.2.2 Consequences of Non-Compliance
Failure to comply with the safety instructions increases the risk of

electric shock and damage to the equipment. Third parties who
approach the installation are also at risk.
If the scheduled maintenance activities are performed only partially or
not at all, damage may occur with associated expensive repair costs.

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Chapter 2 - Safety Instructions 

2.3 Safety Concept
2.3.1 General
The safety regulations in this chapter generally apply when working on

the excitation system. You will find additional instructions and warnings
related to particular topics or actions throughout the manual where
relevant.
The following regulations must be strictly observed:
 The technical specifications and the typical application of the
excitation system (see Chapter 1 - Introduction, Field of Application)
must be strictly adhered to.
 Training of personnel: only trained personnel are allowed to install,
operate, maintain or service the excitation system.
 Modifications without authorization: modifications and constructional
changes of the equipment are not allowed.
 Duty of maintenance: The owner must ensure that the excitation
system is used only under proper conditions and in a fully
serviceable state.
2.3.2 Safety Rules
The following safety procedures according to EN 50110-1 must

absolutely be followed if any (maintenance) work is carried out on the
excitation system:
1 Disconnect completely.
2 Secure against re-connection.
3 Verify that the installation is dead.
4 Carry out grounding and short-circuiting.
5 Provide protection against adjacent live parts.
2.3.3 Residual Danger Areas
Danger areas that cannot be eliminated by technical measures are

clearly marked with warning labels.
The operating voltage in the control cubicles is above 50 V. In the power
part, voltages can reach 300 V ac and short-circuit currents can be very
high. In order to warn personnel against opening the doors during
operation, warning labels are affixed to all cubicle doors.
If the device is built into a whole system, other warning labels are
attached to the inside of the cubicle doors and to the covers of the
power converter modules.
The following residual danger areas must be taken into account when
working on the excitation system:

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 Chapter 2 - Safety Instructions
 Danger from live equipment inside the excitation system, if the

protective covers are removed.
 Hazardous voltage from the rotor field winding and the secondary
side of the excitation transformer.
 Capacitors may still be charged if a power converter cubicle door is
opened immediately after stopping the system.
 Danger from main and auxiliary voltages in cubicles when cubicle
doors are open.
Attention must be paid when installing / replacing the UNITROL 1020.
The unit has large capacitors, which might be charged even after
disconnecting the unit.
An orange blinking LED warns the user in case the internal voltage
exceeds 30 V dc. Depending on the size of the capacitor, discharging
can take a couple of minutes. Do not connect or disconnect the unit
when the LED is still blinking. There is the risk of electric shock.

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2.4 Safety Regulations
2.4.1 Structure of Safety Instructions
Signal Word!
Symbol Situation - Type of Hazard Statement
Possible consequence - Consequence Statement
Essential safety measure - Avoidance Statement
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. Non-observance leads to life-threatening physical
injury or death.
WARNING!
! This symbol indicates a dangerous situation. Non-observance can result

in bad or life-threatening physical injury or death.
CAUTION!
This symbol indicates a dangerous situation. Non-observance can lead
to physical injury or cause damage to the installation.
NOTICE!
This symbol emphasizes important information. Non-observance can
cause damage to the installation or to objects close to it.
IMPORTANT!
This symbol indicates useful information. Not to be used to indicate
dangerous situations.

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2.5 Instructions for Emergency Situations
2.5.1 Firefighting
All personnel must be familiar with the location of fire extinguishers and
emergency exits and must be able to operate the fire extinguishers.
Fire extinguishers are carbon dioxide (CO2) or foam-based.
 CO2 fire extinguishers are intended for fighting fires in electrical
installations and may not be directed at persons.
 Foam extinguishers are intended for fighting fires in non-electrical
equipment. They may be directed at persons but must not be used
for extinguishing fires in electrical equipment.
DANGER!
In case of fire,
Be aware of voltage, toxic gases, overheating.
See the instructions below.
1 Shut down the system.

Operators must be familiar with the emergency shutdown sequence.
2 Put on a protection mask.
3 Use only CO2 to extinguish the fire, no foam, no water.
2.5.2 First Aid Measures for Electrical Installations
In case of an emergency, follow the instructions below:
DANGER!
A person is in contact with electricity.
There is a danger of electric shock for the first aider as well.
Do not touch the person until the system is grounded.
1 Shut down the plant.

Operators must be familiar with the emergency shutdown sequence
of the system.
DANGER!
Residual voltage of the rotating machine is present immediately after
shut-down of the system.
There is a danger of electric shock.
Wait until the system is grounded.

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1 Switch off all power supplies and ground the system.
2 Remove the injured person from the dangerous location.
3 Provide first aid for electric shock.
4 Call for emergency assistance.
2.5.3 Pacemaker
DANGER!
Electrical and magnetic fields.
The system can cause malfunction of pacemakers.
Avoid being close to the excitation system.
Electrical and magnetic fields can influence pacemakers. It is difficult to

predict the general sensitivity of pacemakers.
2.6 Danger signs
Danger signs are attached to any equipment/location with a potential

danger.
The degree and likelihood of such dangers are described by the signal
words DANGER, WARNING and CAUTION. The content of the warning
sign contains information about the respective situation and the
preventive safety measures that must be taken.
Structure of danger signs:
Sign Description
Signal word
DANGER
Situation
Hazardous voltage inside.
Disconnect power and

Essential safety measures
ground equipment before
maintenance work.
Meaning of signal words and consequence statement:
Sign Description of the signal word

DANGER, electrical
DANGER
This symbol indicates imminent danger that will
result in life-threatening physical injury or death.

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WARNING, electrical
WARNING This symbol indicates a possible dangerous situation
that could result in serious physical injury or death.
CAUTION, electrical
CAUTION This symbol indicates a possible dangerous situation
that could result in moderate physical injury. This
signal word can also be used for warnings related to
equipment damage.

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Chapter 3 - Device Overview 

Chapter 3 - Device Overview
3.1 General
Chapter 3 - Device Overview provides the technical data of the device.

This chapter contains:
 Hardware description
 Operation modes and software features
 Parameter description
3.2 Description of the Excitation System
UNITROL 1020 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).
The mechanical construction is extremely compact and robust.
UNITROL 1020 operations are effected through a practical and simple-
to-operate panel on the unit. In addition, user-friendly software facilitates
commissioning and allows optimization of operation.
The UNITROL 1020 unit can be connected to a 40 A Power Module
called UNITROL 1000-PM40. For further information refer to the
separate User Manual.

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 Chapter 3 - Device Overview
3.3 Hardware
Casing
The device’s base is an aluminum back plane.
Cooling is done by the main heat sink on top of
the device. The unit itself is covered with plastic
and provides an IP20 protection.
Power electronics
The power part is fitted with an IGBT semi-
conductor. The average value of the output
280.25 mm voltage is always positive. The output is current-
302 mm limited and thus short-circuit-proof.
Control elements
The display panel and connectors for the USB
and Ethernet interface are located on the unit
cover.
Installation
The site of installation must be dry and free of
147.5 mm
dust.
170 mm
3.3.1 Connection Diagram
Digital I/Os
Analog I/Os
UNITROL 1020
AUX L1
Measurement
~
and control
UNET AUX L2
= AUX L3
inputs
UM ETH
USB
AVR
IM2
RS- 485
PWM CAN
ExCap(-)
Supply
power electronics
Ie -
PWR L1
SM E
E PWR L2
Ie PWR L3
+

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3.3.2 Control Interfaces
The UN1020 device can be operated and controlled in different ways as described in the
rest of this section.
3.3.2.1 Digital and analog IO
The UN1020 can be controlled by means of digital and analog inputs and can therefore set
up several configurations to fulfill most target applications. Digital and analog IO has
highest priority and cannot be overridden by any other controls.
3.3.2.2 Keyboard and Panel Display
The 4-line display and the 8 keys allow full operation.

REM 100.0% S
AUTO NoLoad
All settings can be carried out directly on the unit without
0.00 % UM additional equipment:
0.00 A Ie
SETPNT 12:45 MENU  Configuration of inputs and outputs
 Parameter setting
 Display of important measuring values.
The operation of the Panel is described in detail in section

6.3 Panel Operation.
3.3.2.3 Remote Access using MODBUS protocol
The Remote Access feature allows device access and control from local or remote
locations by using MODBUS as application protocol. The communication can be
performed either via RS485 or Ethernet. More information about the connection
possibilities can be found in Chapter 3.3.9 - Communication Ports.
Basic features and advantage of Remote Access

 Configuration of parameters and I/O signals.
 Measurement reading.
 Setpoint adjustment and PID tuning.
 Possibility to create a custom application that uses Remote Access to fully control the
device.
 Monitor only and full control possible.
The Remote Access feature is fully interoperable with the CMT1000 software; both
interfaces can access and read from the device at the same moment. Control permission
(write parameters) is handled automatically by the AVR microcontroller. The Remote
Access feature is described in detail in Chapter 3.4.6 - Modbus for Remote Access.

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3.3.2.4 Terminal Blocks
The terminal blocks are separated regarding their functions, see following figure.
Figure 3-1Terminal Block of UN1020

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IM2 UNET UM IE UPWR &UAUX PE
AUXL1(+)
PWR L2
PWR L3
AUXL2(-)
PWR L1
AUX L3
ExCap(-)
MC2 +
MC2 -
NW3
NW1
ML3
ML2
ML1
IE -
IE+
PE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Jumper will short-circuit power input with auxiliary input
Ref. Label Signal Description

1 MC2- Machine Current -
2 MC2+ Machine Current +
3 NW3 Network L3
4 NW1 Network L1
5 ML3 Machine L3
6 ML2 Machine L2
7 ML1 Machine L1
8 ExCap(-) External Capacitor -
9 IE - Exciter Current -
10 IE + Exciter Current +
11* AUX L3 Power Supply L3
12* PWR L3 Main L3
13* AUX L2(-) Power Supply L2 (-)
14* PWR L2 Main L2
15* AUX L1(+) Power Supply L1 (+)
16* PWR L1 Main L1
17 PE Protection Earth
*Jumpers can be used to shorten excitation power input with control power Uaux input in
order to reduce wiring

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20 38 40 52
BRN
BRP
BO2
BO1
D12
D10
G2
D8
D6
D4
D2
BI3
BI2
BI1
V6
V4
V2
ARN
ARP
AO2
AO1
D11
G1
D9
D7
D5
D3
D1
V5
V3
V1
AI3
AI2
AI1
21 39 41 53

20 G2 GND
21 G1 GND
22 D12 Digital Input 12
26 V6 24V Power
27 V5 24V Power
Digital IO Terminal
28 D8 Digital Input / Output 8

32 V4 24V Power
33 V3 24V Power
38 V2 24V Power
39 V1 24V Power

40 BO2 GND Analog Output 2
Analog IO Terminal
41 AO2 Analog Output 2

42 BO1 GND Analog Output 1
43 AO1 Analog Output 1
44 BRN GND Negative Reference
45 ARN -10V Negative Reference
46 BRP GND Positive Reference
47 ARP +10V Positive Reference

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48 BI3 Analog Input 3 –
Analog IO Term. 49 AI3 Analog Input 3 +
51 AI2 Analog Input 2 +
53 AI1 Analog Input 1 +
70 72 74 76
71 73 75 77
Remark:
RS-485 CAN The jumpers must be
plugged as shown in
the drawing on the left.
X1300 X1302

70 RH RS-485 +
RS-485 / CAN Terminal
71 CH CAN High
72 RS RS-485 shield
73 CS CAN Shield
74 RL RS-485 -
75 CL CAN Low
76 CV CAN Power 5V
77 CG CAN GND

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D804
D802
USB Ethernet
D800
Pin Label Signal Description

1 Transmitter +
2 Transmitter –
3 Receiver +
4 Do not use [connected to magnetics]
Ethernet

6 Receiver –
LED Green ETH Link OK
LED Yellow ETH Data Traffic
1 USB Power 5V
USB
2 Data -
3 Data +
4 GND
Ref. Color Description
D800 Green Power ON status
ON: DSP and MCU is powered
Blinking: Target SW is running
Status LEDs
D802 Yellow Excitation ON, Blinking: Limiter active

D804 Red Device status
ON: Alarm or trip active
Blinking:
Startup failure, target could not load parameters
Excitation output is blocked
Save parameter to EEPROM first before starting excitation

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RS232
on
RJ45
Key board panel can be mounted inside front panel. Following additional
equipment can be ordered:
Panel connector
Door mouning kit:

OPMP-01-Kit: Mounting Cabinet Panel ACS 3AUA0000013086
RJ45 cables:
RJ45 CAT 5e SF/UTP, gray 1,5 meter 3BHE027825R0150
RJ45 CAT 5e SF/UTP, gray 3.0 meter 3BHE027825R0300

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3.3.3 Block Diagram
(+10 V) +Vref AUX L1

(-10 V) -Vref
AUX L2
(+24 V) +Vdig UAUX
AGND AUX L3
PE
DGND
PWR L1 IE+
PWR L2 IE-
Main Ie
PWR L3 ExCap
RS-485
RL
RH VDC
ML1 L1 or
Machine ML2 PID X1300 Remote
L2
voltage ML3 L3 RS Access
MC2+ positive CAN Bus

Machine gnd CG
MC2- negative
current CH
DSP CL
NW1
Network X1302 CAN
voltage NW3
CS
ETH
CMT1000 USB 2.0
or Remote 4 pol CMT1000
Access or Remote
AI1 to AI3
Access
BI1 to BI3 AO1

ARP +10V # AGND BO1
Analog Analog
BRP AGND ~ AO2
inputs
ARN -10V
# ~ AGND BO2
output
BRN AGND
in, norm.
+24V V1 to V4
V5, V6 +24V norm.
D1 to D8 Digital
D9 to D12 in, inv.
Digital IO's
out, inv.
inputs
G2 DGND inv. DGND G1
out, norm.

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3.3.4 Device Connectors
Terminal Signal Circuit

designation
Auxiliary Power Supply UAUX Absolute max. values
15 = AUX L1 - Auxiliary Power Supply L1 (+) 3~
13 = AUX L2 - Auxiliary Power Supply L2 (-) 9 ... 300 Vac L1,L2,L3
11 = AUX L3 - Auxiliary Power Supply L3
1~
16 ... 300 Vac L1, L2
2=
18 ... 300 Vdc L1, L2
Power Electronics Supply UPWR Absolute max. values

16 = PWR L1 - Main L1 3~
14 = PWR L2 - Main L2 0 ... 300 Vac L1,L2,L3
12 = PWR L3 - Main L3
1~
0 ... 300 Vac L1, L2
Remark: Max inrush current
(average) must not exceed 200 A 2=
within 10ms (See chapter 4.5.1). 0 ... 300 Vdc L1, L2
External Capacitor
8 = ExCap(-) Capacitor: 1000 µF, 450 V IE-
External
ExCap(-)
Types:
+
E
PEH200YK410TM IE+
PEH169YO4100M Wiring must be within 0.1 Ohm and 0.5uH in series
Requirements:
min. Voltage: >=450 V
Temp. Range: -40...85 °C Warning:
Oper. lifetime at 85 °C: >5000 h Reverse polarity of external capacitor
Rip. curr. at 100 Hz at 85 °C: >5 A will damage device
ESR 20 °C 100 Hz: <120 mOhm
Machine Voltage three-phase UM External
7 = ML1 - Machine L1
ML1
ML2
ML3
max. 500 V / 0.2 VA
Warning: If Um > 250 Vac, then
the starpoint must be connected
*
to PE
SM
MC2+ 1A / 5 A
Machine Current single-phase IM2 IM2 0.1 VA
MC2-
2 = MC2+ - Machine Current +
1 = MC2- - Machine Current -
External
*
Machine Voltage single-phase UM ML1
7 = ML1 - Main L1 ML3
5 = ML3 - Main L3
* max. 500 V / 0.2 VA
Machine Voltage three-phase with External

ground UM ML1
7 = ML1 - Machine L1 ML2
6 = ML2 - Machine L2 ML3
5 = ML3 - Machine L3 L1 L2 L3 * max. 500 V / 0.2 VA
*PT & CTs must be grounded
Line Voltage measurement single-

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phase UNET External

4 = NW1 Network L1 NW1
3 = NW3 Network L3 NW3
*PT & CTs must be grounded * max. 500 V / 0.2 VA
Excitation Current Output Ie External

IE+
10 = IE + - Exciter Current +
9 = IE - - Exciter Current -
0 to 300 V=
20 A = E
IE-
17 = PE Protection Earth

Designation
Digital input / output
External
24V
37 = D1 Digital Input / Output 1 V1
V2
36 = D2 Digital Input / Output 2 20 ... 28 V
35 = D3 Digital Input / Output 3
31 = D5 Digital Input / Output 5 D1 ADC
30 = D6 Digital Input / Output 6 2k

29 = D7 Digital Input / Output 7 G1

External
Caution: 24V
V1
Configured as outputs, DIO1 … V2
20 ... 28 V
DIO8 must not be connected

directly with 24 V Power (causes
short circuit via internal transistor) D1
max. 150 mA
24V Power
39 = V1 24V Power G1
38 = V2 24V Power
33 = V3 24V Power
32 = V4
GND
20 = G2 GND
21 = G1
Digital input only
25 = D9 Digital Input 9
27 = V5 24V Power
26 = V6 24V Power
20 = G2 GND
Note: The internal 24 V supply (V1 to V6) can be loaded with a maximum of 600 mA by
all used digital inputs and outputs.

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Designation
53 = AI1, 52 = BI1 Analog Inputs External 10 V DC
ARP
51 = AI2, 50 = BI2 AIx/BIx 4.7k
100k
AI1
49 = AI3, 48 = BI3 R
47k
+
10k
Signal bandwidth 100Hz BI1
-
47 = ARP BRP
100k
47k
45 = ARN +10 V pos Ref 4.7k
AGND
ARN
-10 V neg Ref -10 V DC
BRP = 46 External
BRN = 44 GND Positive Reference max. ±10 V
AI1 + 100k
GND Negative Reference +
47k
BI1 -
-
100k
R = 10kOhm (+-5V input 47k
range)
Analog Inputs digitally
assigned 10 V DC
53 = AI1, 52 = BI1 AIx/BIx ARP
51 = AI2, 50 = BI2 4.7k
100k
AI1
49 = AI3, 48 = BI3 see Chapter 3.3.7 - Analog + Ain
Inputs 47k
BI1
-
100k
47k
Analog Outputs
AOx to BOx max. ±10 V
43 = AO1 (AGND = BO1, BO2) + AO1
41 = AO2 -
42 = BO1 Max. output current: 10mA
40 = BO2 BO1
Serial interface RS-485

RH
72 = RS RS-485_SHIELD +
RS
RS485+
RS485_SHIELD
70 = RH RS-485 + - RL RS485-
74 = RL RS-485 – +
5V
Two jumpers X1300 for - X1300
the bus terminating

resistor.
Jumpers must be placed at

both ends of the bus
CAN Bus CG CAN_GND
CL
77 = CG CAN_GND +
CS
CAN_L
CAN_SHIELD
75 = CL CAN_L - CH CAN_H
VC CAN_POWER
73 = CS CAN_SHIELD +
71 = CH CAN_H X1302
-
Two jumpers X1302 for
See terminals the bus terminating
resistor.
Jumpers must be placed at

both ends of the bus

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3.3.5 Digital Inputs
Input Function Description

None Input not assigned
Excitation ON active Excitation ON command active:
- Field flashing begins if Off Level > 0%
- Auto mode: Soft start begins after the Off Level has been reached, and
rises up to the Auto Initial Setpoint.
- Other modes: Initial Setpoint is used.
Excitation ON not active Excitation ON command not active: Mode Initial Setpoint
All setpoints are immediately set to their Auto 100%
initial values and remain fixed there (see Manual 0%
table on the right). Open Loop 0%
Auto, Manual and Open loop Initial PF 1.0
setpoints can be changed from there Var 0%
Gen CB Closed Status standard start-up
Circuit-breaker values.
closed status active:
active - Activates current measurement
- This message immediately triggers the ramp of the Soft start as if still the
hold time.
Gen CB Closed Status Circuit-breaker closed status changes Mode Final Value
no longer active from active to not active. All setpoints are Manual 90% Ie No Load
immediately set to the following values:
Open Loop 90% 1/Kceil
Auto 100%
Parallel with Grid Status Parallel with grid status active:
- With Gen CB Closed, enables changeover to PF and Var modes.
- Disables VDC mode.
Connecting unit parallel with grid action:
Depending on Parameter “Enable PF/VAR initial SP”, SP before parallel
with grid status is taken over or SP is changed to initial value.
Disconnecting unit from grid action:
Depending on the parameter “Loose grid go to initial SP”, AUTO SP is
taken from the initial SP instead of keeping the same operation point.
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 goes Manual Ie No Load
to the following value at ramp speed: Open Loop 100% 1/Kceil
PF 1.0
Depending on parameter “Reset SP to Var 0%
initial value”, SP of defined final values or Auto 100%
initial values are taken over
Remote SP Enable When active it enables the setpoint adjustment from an analog input
(remote setpoints should be configured in the Analog Input section).
PF Enable Activates Power factor regulation. (Requires the PF/VAR SW)
Var Enable Activates Reactive power regulation. (Requires the PF/VAR SW)
Manual Enable Activates Manual operation mode (field current regulation).
Open Loop Enable Open loop, direct control of power transistor active
Synchronize Activates Synchronization or Voltage Matching: If Synchronization SW
(optional) is not available in the device, the input signal will activate Voltage
Matching only. (Requires Synchronization SW)
VDC Enable Activates the Voltage Droop Compensation (VDC) control mode. (Requires
Voltage Droop Compensation (VDC) SW)

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Secondary Net 1 Selects the Secondary Net for VDC operation.
Binary coding to select 4 net IDs or left side breaker in ring structure.
(Requires Voltage Droop Compensation (VDC) SW)
Secondary Net 2 Selects the Secondary Net for VDC operation.
Binary coding to select 4 net IDs or left side breaker in ring structure.
(Requires Voltage Droop Compensation (VDC) SW)
Reset Alarm Clear the following alarms: (Requires Double Channel SW)
- Supervision Alarm 1 and 2
- Supervision Trip
- Switch over
- Monitor Alarm 1 and 2
Standby When the AVR is in Standby mode:
- The excitation output of the AVR is turned off
- Boost is disabled
- Field flashing is off
- Integrator is kept in 1/Kceiling
- All limits are disabled
- No VDC data is transmitted via RS-485.
- The AVR displays Standby as Operation Mode.
- DCH Follow-up1 operates, only if DCH communication is active; otherwise
the Channel Follow-up operates instead. For more information see
Chapter 3.4.4.4.8 - DCH Follow-Up and 3.4.1.5 - Channel Follow-up.
- Alarm and Trip statuses1 output their values via digital outputs only if they
are configured to behave like that. For more information see Chapter
3.4.4.4.2 - DCH Supervision.
RC Fieldbus Block It disables the Fieldbus communication in local operation.

All control registers are reset to default, excitation is switched off if
controlled over Modbus
(Requires Modbus Option)
FCB closed Status Field circuit breaker closed status active.
External Alarm Input to use as External Alarm input.
EmergencyExcitationOff Excitation OFF command, overwrites Excitation ON input and Modbus
control input
PSS enable Enables PSS. In case digital IO is selected, PSS is blocked when digital
input is not activated
(Requires PSS Option)
Gain Reduction Reduces the gain of PID tuning (AUTO and PF/VAR) by factor 2
Sync Dead Bus Enable Enables dead bus synchronization, Unet < 5%
Synchrocheck Enables synchrocheck function, voltage matching is disabled
Unload VAR Regulates VAR to 0, command must be activated until VAR reaches 0
Line Charging Second parameter set for soft start, activated with new digital input "Line
Charging"
3.3.5.1 Polarity
Polarity can be configured for all digital input/output ports separately, and each one has a
separate polarity configuration when configured as input or output. Each DIO port can be
configured as only input or only output at the same time.

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24 V DC 24 V DC
inverted
DIO1 to 8 DIO1 to 8
DI9 to 12 DI9 to 12
normal DI13 to 18 DI13 to 18
3.3.5.2 Forcing Digital Input Signals
Each digital input signal can be set to a predefined value (i.e. active/not active) by means
of configuration, without the need to make connections at the device's terminals; this
process is also known as forcing.
Forcing a digital input terminal can be done by configuring the Polarity parameter of an
input to Normal or Inverted. When Polarity is set to Normal, the digital input is set to not
active, i.e. false or logical 0. When it is set to Inverted, the input is set to active, i.e. true
or logical 1. The digital input which is being configured, must not be wired at the device
terminals. For more information about configuration see Chapter 6 - Operation.
3.3.6 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 build up) active, if Excitation ON.
See section 3.4.2.2 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 Reserved signal, do not use
Limit Active One of the limiters (V/Hz, Ie, PQ, UM or Im) 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 Maximum setpoint has been reached
Reached
Operational Limit Ie, PQ, UM, Im limiter or Diode Alarm active
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 under-run,
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 plus hysteresis exceeded
Not dependent on signal Excitation ON.
Close CB Command The command is released:

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(
Requires Synchronization - Angle is in a value where it would take the Total CB Closing Time for
SW)
the breaker to close at zero degrees with current speed and
acceleration.
- Sync Check demand active
- The command is active as long as the command Sync Check is active
Sync Check (Requires Sync Check demand to be active:
Synchronization SW) - Generator circuit breaker is open
- Machine voltage is higher 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
Sync Speed increase Control signal to governor to increase speed, pulses (Requires
Synchronization SW).
Sync Speed decrease Control signal to governor to decrease speed, pulses (Requires
Synchronization SW).
Switch Over Control signal to 2nd channel to take over control (Requires Double Channel
SW).
Supervision Trip Trip indication, depending on the activated monitor functions (Requires
Double Channel SW)
Supervision Alarm indication, depending on the activated monitor functions (Requires
Alarm 1 Double Channel SW)
Supervision Alarm indication, depending on the activated monitor functions (Requires
Alarm 2 Double Channel SW)
Monitor Alarm 1 Alarm indication, depending on the activated monitor functions (Requires
Double Channel SW)
Monitor Alarm 2 Alarm indication, depending on the activated monitor functions (Requires
Double Channel SW)
Diode Alarm Event of open diode (Requires Rotating Diode Monitoring SW)
Diode Trip Event of a shorted diode (Requires Rotating Diode Monitoring SW)
PSS Active Indication that PSS is contributing (Requires PSS SW)
Close FCB Command Close command for FCB
Open FCB Command Open command for FCB
FRT Detection Fault ride through indication
(Sudden voltage dip at network)
ExcON status Indication that Excitation is ON
Softstart Active Indication that Softstart is still active (ramping up of the SP)
Manual Active Indication that Manual mode is active
PF VAR Active Indication that PF/VAR mode is active
3.3.6.1 Polarity
Polarity can be configured for all digital input/output ports separately, and each one has a
separate polarity configuration when configured as input or output. Each DIO port can be
configured as only input or only output at the same time.
3.3.6.2 Forcing Digital Output Signals
Each digital output can be forced for test purposes by inverting its polarity. This will even
work when no output signal is selected.

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3.3.7 Analog Inputs

None Input not assigned
Auto Remote Setpoint External setpoint input to Auto regulator
PF Remote Setpoint (Requires External setpoint input to PF regulator
PF/VAR SW)
Var Remote Setpoint (Requires External setpoint input to Var regulator
PF/VAR SW)
Manual Remote Setpoint External setpoint input to Manual regulator
Open Loop Remote SP External setpoint input to open loop
UM Aux (Requires UM AUX SW) Auxiliary supply to the summing point of Auto regulator
VAR Aux Measurement Auxiliary supply to the summing point of the PF/VAR regulator
Cooling Media Temperature Input temperature measurement for the temperature influence limiter
Ie External Reserved for real-time simulator
PSS Power Injection PSS power injection point, scaling see PSS test interface
(Requires PSS SW)
PSS Frequency Injection PSS frequency injection point, scaling see PSS test interface
(Requires PSS SW)
PSS LeadLag Injection PSS lead lag injection point, scaling see PSS test interface
(Requires PSS SW)
PSS External Input Input for external PSS signal
(Requires PSS SW)
Digital Input 13(+) & 14(-) Assign digital inputs
Note: When configuring an external setpoint from the analog input list shown above, the
"Remote SP Enable" digital input should also be configured. For more information see
Chapter 3.3.5 Digital Inputs.
3.3.7.1 Level of the Analog Inputs
A minimum and maximum voltage level can be set for every analog input. This level
represents a defined scaling, which is shown in the table below.
Input Function Uin0% Uin100% Remarks

Min (-10… +10 V) Max (-10…10 V)
Auto Remote Setpoint Auto setpoint min Auto setpoint max See Chapter 3.4.1.1
PF Remote Setpoint PF setpoint min PF setpoint max See Chapter 3.4.1.1
(Requires PF/VAR SW)
Var Remote Setpoint PF setpoint min PF setpoint max See Chapter 3.4.1.1
(Requires PF/VAR SW)
Manual Remote Setpoint PF setpoint min PF setpoint max See Chapter 3.4.1.1
Open Loop Remote SP PF setpoint min PF setpoint max See Chapter 3.4.1.1
UM aux UM Aux min UM Aux max Range – 100% to +100%
VAR Aux Measurement -10% +10% Fix scaling
Cooling Media Temperature -100 °C +100 °C Fix scaling
Ie External Ie Ext Range min Ie Ext Range max
PSS Power Injection Neg. peak value Pos. peak value Scaling from 1% to 10%
(Requires PSS SW)
PSS Frequency Injection Neg. peak value Pos. peak value Scaling from 0.1% to 1.0%
(Requires PSS SW)
PSS LeadLag Injection Neg. peak value Pos. peak value Scaling from 0.1% to 1.0%
(Requires PSS SW)
PSS External Input -25% UM +25% UM Range symmetrically
(Requires PSS SW) adjustable

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Input Function Uin0% Uin100% Remarks
Min (-10… +10 V) Max (-10…10 V)
Digital Input 13(+) & 14(-) Set to 2.0 V Set to 5.0 V See graphic below
Internal signal value [%]

External setpoint input
Setpoint max
Setpoint min
Ext. Setpoint Auto
-10 10 [V]
Uin0% Uin100%
UM Aux [%]
Input to the summing 10
point 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
DI13 = 1
Condition of the
digital inputs
-5.0 -2.0 DI13 = 0
DI14 = 0 Uin
(DI 13 to DI18) 2.0 5.0 [V]
DI14 = 1
Status of the digital -> Din13(+) =0 -> Din13(+) =1
inputs -> Din14(-) =1 -> Din14(-) =0
Note: AI and BI must not be active simultaneously, DI13 and DI14 will both be “0”

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3.3.8 Analog Outputs
None Output not assigned

Excitation Current Excitation current
PWM Pulse width modulation, control value is scaled from 0 to 100%. It
represents the actual field voltage output of 0.5 to 99%
Ue Field Voltage Excitation voltage (absolute)
Upwr DC Link Received excitation input power voltage
Voltage
Um relative Machine terminal voltage
Active Power Machine active power (relative)
VAR relative Machine VAR relative
PF absolute Machine PF absolute, negative: -Q / positive for +Q
Fbias Analog continuous signal presenting difference between UNET and UM
Fbias = fNET – fNOM – (SlipMAX – SlipMIN)/2- SlipMIN
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
Slip Slip between Network and Machine frequencies
PSS TP output 1 PSS test point 1, select signal over PSS test interface in CMT1000
PSS TP output 2 PSS test point 2, select signal over PSS test interface in CMT1000
Note: The assignment of the analog outputs to the 2 terminals AO1 and AO2 can be
selected freely.
3.3.8.1 Level of the Analog Outputs
A minimum and maximum voltage level can be set for every analog output. This level
represents a defined scaling, which is shown in the table below.
Output Function Uout0% Uout100% Remarks

Min (-10… +10 V) Max (-10…10 V)
Excitation Current Ie Range min Ie Range max Scaling: 0% … 400%
PWM 0% (fix) 100% fix
Ue Field Voltage 0V (fix) Ue Field Voltage Range: 0 to 500 V
max
Upwr DC Link 0V (fix) Upwr DC Link Range: 0 to 500 V
Voltage Voltage max
Um relative 0V (fix) Um relative max Range: 0% … 400%
Active Power Active Power min Active Power max Range: -200% … +200%
VAR relative Negative VAR max VAR max Range: 0% … 200%
PF absolute Min PF setpoint Max PF setpoint Scaling according to min/max
PF setpoint
Fbias Fbis min Fbias max Range: -10 to +10 Hz
Slip Negative Slip max Slip max Range: 0 to 10 Hz
PSS TP output 1 Neg. peak value Pos.peak value Scaling depending on PSS test
interface settings
PSS TP output 2 Neg. peak value Pos.peak value Scaling depending on PSS test
interface settings

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Excitation Current
Caution:
Ie0% must be less than
Ie100%
Fbias
PWM Output
Aout [V]
Slip 10
Uout 100%
(max) Slip
* The parameter "Slip0%"
cannot be set by the user. -10 10 [Hz]
This parameter is internally Uout 0%
set as the negative of "Slip (min)
100%": -10
"Slip0%" = (-)"Slip100%" Slip 0% * Slip 100% *
(min) (max)
Aout [V]
10
ActivePower Uout 100%
(max)
ActivePower
200 [%]
Uout 0%
(min)
-10
ActivePower 100%
(max)

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3.3.8.2 Forcing Analog Outputs
Analog outputs can be forced to a certain level by selecting the min and max voltage
level to the same value.
3.3.9 Communication Ports
UN1020 has three main communication ports to share several features that can be used
in combination to cover the requirements of an application.
 USB is a point-to-point interface that can be used to connect the UNITROL 1020
with a PC and is used by the CMT1000 software to control the device.
 The Ethernet port is used to connect the UNITROL 1020 to a multiple point
Ethernet network in order to connect the CMT1000 remotely and to access the
UNITROL 1020 by a plant control system in parallel.
 RS-485 is a multi-point interface that could be used for Remote Access (Modbus
RTU) or VDC; only one feature can be used at the same time.
 CAN is a multi-point interface used to connect a UN1000-PM40 module and uses
the Double Channel feature for setpoint follow-up of the second channel. Only one
of the above features can be used at same time.
This section describes the hardware and wiring requirements for the communication
interfaces. The software features that use these communication interfaces are explained
in Chapter 3.4 Software.
3.3.9.1 USB Interface
The serial USB port of UN1020 can be used to connect a PC that runs a CMT1000
software. Max. USB cable length is 3 m. The USB port will power up control devices of
UNITROL 1020 in order to allow the user to download or upload files to the unit without
additional power supply connection.
Figure 3-2 USB connection to a PC
NOTICE!
Use only the USB cable that is supplied with the device. Using
another cable might cause communication failure or power over
USB might not work correctly so that the device does not start.

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3.3.9.2 Ethernet Interface
Figure 3-3 Ethernet TCP/IP connection
The Ethernet TCP/IP connection:

 Ethernet allows monitoring and control from a remote location.
 Max. one CMT1000 connection can simultaneously access the AVR
 Multiple Remote Control connections can simultaneously access the AVR
 Open TCP Ports
1 Device detection. (Port 5002/5003)
Ethernet scanning (CMT1000 function)
2 Modbus TCP (Port 502)
3 SNTP client (Port123)
More information about these software features and configuration can be found in
Chapters 3.4.6 Modbus for Remote Access and 6.4 PC Software Tool.

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3.3.9.3 RS485 Interface
UN1020 provides a RS485 interface for both VDC and Remote Access; however only
one can be operated with the RS485 interface. If both features are simultaneously
required, the solution is the usage of Remote Access over Modbus TCP and VDC over
RS485.
Figure 3-4 ABB solution if both Remote Access and VDC features are required.
The electrical connections of the RS485 bus should be performed according to EIA485
standard specification. The 120 Ohm resistor that is normally used to terminate a RS485
bus is already included in UN1020 and should be used by placing a jumper bridge over
the X1300 terminals. The X1300 location is shown in Chapter 3.3.2.4 Terminal Block.
Cable type requirements
 Cable cross-section: 2 x 0.25 mm2
 Cable impedance: 100 to 120 Ohm
 Shielded twisted pair.
 500 m max cable length
(in case of UNITROL 1000-15 the bus is only 250 m)
Bus topology
 31 devices maximum for single channel and 62 for dual channel configuration.
 57.6 kBaud
The cable shielding shall be grounded as closely as possible to the device's terminals as
shown in the figure below.

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485 CAN
- gnd
- 5V Shield
+
RH RL RS CG CH CL CV CS
CAN
X1302
RH RS RL CV
CH CS CL CG
RS-485 Max.
X1300 30 mm
Shielding
should be
grounded.
Figure 3-5 Shielding and wiring recommendation when using the RS-485 interface.
The signal line shield must be connected only at one location to PE, typically at the end
of the line.
RS485 for VDC and remote access
When configuring the RS485 interface for VDC or remote access, a jumper bridge must
be placed over the X1300 terminals of each AVR located at the end of the bus; and it
should be removed from those not located at the end (see Figure 3-6). No resistor should
be placed externally, i.e. on the device's terminals, when the jumper bridge of the
UN1020 is already being used.
X1300 X1300
X1300 AVR 1 AVR 2 AVR 3 AVR 4 X1300

+
RH 1 RS-485 1 RH 1 RS-485 1 RH 1 RS-485 1 RH +
- RL 2 2 RL 2 2 RL 2 2 RL -
RS RS RS RS
Figure 3-6 RS-485 wiring and jumper settings to use VDC on a set of four AVRs.
As shown in Figure 3-6 the topology of the bus should be as "one line" with two endings,
and not as a "star". The recommendations described in Chapter 3.3.9.3 RS485 Interface
should be strictly followed. The VDC feature operates only over RS485 and could not
work properly if there is any other device incompatibly connected to the same bus.
The VDC software should be configured in each device prior to use. The configuration is
described in Chapter 3.4.3.1 Voltage Droop Compensation (VDC).
3.3.9.4 CAN Interface
A CAN interface is provided for both Double Channel (connection with a second channel)
and UN1000-PM; however both cannot use the bus simultaneously. As will be explained
in Chapter 3.4.4.4 - Double Channel (DCH), the DCH Supervision can be used together
with a UN1000-PM connected to the AVR since the CAN communication is not needed
for the operation of the monitoring functions. However, the remaining functions from
Double Channel are not compatible with the UN1000-PM. For more information see
Chapter 3.4.4.4.9 - DCH Communication: Configuration and Compatibility.

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The electrical connections should be performed according to CAN standard guidelines. A

120 ohm resistor normally used to terminate the bus, is already included in the device
and can be used by placing a jumper bridge over the X1302 terminals. The location of the
X1302 terminals can be identified by referring to Chapter 3.3.2.4 Terminal Block.
The CAN interface cannot be used for remote access and for any other purpose not
explicitly indicated in this user manual.
CAN for UN1000-PM40
For more information see the UN1000-PM40 User Manual.
CAN for Double Channel
When using Double Channel, the CAN connections should be performed as shown in the
figure below (CAN connection for Double Channel SW). The cable used for the CAN
communication has to be connected between the two channels, i.e. Main and Redundant,
and not to any other device. To properly terminate the bus, place one jumper bridge over
the X1302 terminals of each device.
Cable type requirements

 Cable cross-section: 2 x 2 x 0.34 mm2
 Cable impedance: 120 Ohm
 Maximum cable length: 30 meters.
 Shielded twisted pair. The cable shielding must be grounded.
The Double Channel is an optional feature that should be previously activated in the
device (by password or product rubric), configured and the communication activated. For
more information refer to Chapter 3.4.4.4- Double Channel (DCH).
485 CAN 485 CAN

- gnd
- 5V Shield
- gnd
- 5V Shield
+
+
+
+
RH RL RS CG CH CL CV CS RH RL RS CG CH CL CV CS
RS-485 RS-485
Channel 1 X1300 Channel 2 X1300
RH RS RL CV RH RS RL CV
CH CS CL CG CH CS CL CG
CAN CAN
X1302 X1302
Shielding Shielding
Double Channel CAN Communication
Figure 3-7 CAN connection for Double Channel SW

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3.4 Software
The UN1020 device supports several operating modes and software features, such as
machine voltage regulator (Auto), field regulator (Manual), measurements monitoring
and others which are described in detail in this section.
There are three different SW function packages defined as BASIC and FULL packages
(and PSS as option only). The table below shows the configurations.
A set of basic software features is enabled by default in each UN1020 product and is
referred to as basic software package. There are optional software features which
extend the UN1020 capabilities and which can be enabled by password.
No. SW-Option Name Descriptions BASIC / See

(Figure 6-16) FULL/ chapter
Option
1 AVR/FCR/PF/VAR PF / Var Regulator BASIC 3.4.1.3
2 Limiters Limiters BASIC 3.4.4
3 Soft Start Soft Start BASIC 3.4.2.1
4 Voltage Matching Voltage Matching BASIC 3.4.2.6
5 VDC Voltage Droop Compensation BASIC 3.4.3.1
6 UMAUX Auxiliary Supply to Summing Point BASIC 3.3.7
7 Modbus Modbus TCP for remote access BASIC 3.4.6
8 RDM Rotating Diode Monitoring BASIC 3.4.4.5
9 Double Channel Double Channel and supervision BASIC 3.4.4.4
functions
10 Synchronization Synchronization BASIC 3.4.2.7
11 Extended Data Logger Non-volatile Data logger FULL 3.4.4.6
12 Event Recorder Non-volatile Event Recorder FULL 3.4.4.7
13 External Ie Meas. External current measurement Option 3.3.7 or
 Must only be used with real 3.3.9
time simulator
14 PSS Power System Stabilizer Option 3.4.5.4
Once a password code has been acquired from ABB, an optional software feature can
be enabled using the CMT1000 software. A pre-configured device with selected
optional features can also be ordered by means of the product rubric number, and in
this case there is no need for software activation by password. More information
regarding the activation procedure can be found in Chapter 6.4.5 Menu Structure of
CMT1000.
The following sections explain the complete UN1020 software including optional
features. It is clearly mentioned at the beginning of the description if a software feature
is optional or not. The Panel and CMT1000 software are explained in Chapter 6 -
Operation.
After the configuration of the device, the parameters should be stored in the non-
volatile EEPROM memory; otherwise the changes are lost after restarting the device.
The command Save to the EEPROM is used to store parameters in the non-volatile
memory and is explained in Chapter 6 - Operation.

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3.4.1 Operating Modes
There is a bumpless changeover between all modes performed by the Channel Follow-up
function. For more information see Chapter 3.4.1.5 - Channel Follow-up. Tuning and
other parameters are described in Chapter 3.4.1.6 - Description of Parameters.
3.4.1.1 Automatic Voltage Regulation (Auto)
Regulates the terminal voltage of the

synchronous machine. PID Regulator
Note:
Current measurement for compensation /
droop SM E
3.4.1.2 Manual Control
Regulates the field current of the

excitation machine.
PI Regulator
Note:
No limiters are active as long as this
mode is active.
SM E
3.4.1.3 PF or Var Regulation
Regulates the power factor or reactive

power of the synchronous machine. PID Regulator
PF
Remark: MVar
Var setpoint is normalized at 1pu terminal voltage
of the generator
SM E
3.4.1.4 Open Loop
Control with a fixed output signal.
Note:
No limiters are active as long as this
mode is active.
SM E

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3.4.1.5 Channel Follow-up
While the UN1020 device is operating at an operating mode, the setpoint from the other
modes are following the actual one in order to provide a soft transition, with no bumps
(e.g. from Auto to Manual). This feature is called Channel Follow-up.
3.4.1.6 Description of Parameters
System Data
Nominal excitation current: Ie Nominal [A]
Measuring voltage three- or single- PT [Single_Phase] PTNET
phase: [Three_Phase] UNET
[Three_ph_gnd] f Nominal PTM
UM Primary UM Secondary Regulator
Nominal voltage of the Machine: UM Nominal [kV]
Potent. transformer, prim. voltage: UM Primary [kV] IM2 Primary
Potent. transformer, sec. voltage: UM Secondary [V] IM2 Secondary
Nominal voltage of the Network: UNET Nominal [kV] IM2 Nominal

UM Nominal
Potent. transformer, prim. voltage: UNET Primary [kV] Ie Nominal
Potent. transformer, sec. voltage: UNET Secondary[V] Ie No Load
SM E
Xq
Nominal machine current IM2 Nominal [A]
Current transformer primary: IM2 Primary [A]
Current transformer secondary: IM2 Secondary [A]
No load excitation current: Ie No Load [%]
Ceiling factor: Kceil [V/V]
Machine reactance: Xq [p.u.]
Frequency nominal: f Nominal [Hz]
Single phase machine Checkbox
IMPORTANT!
If there is a block transformer with any circuit configuration between PT M and
PTNET, the phase shift must be compensated. The phase can be
compensated as described in Chapter 3.4.2.7 Synchronization (SYNC).
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
Auto, Manual and Open Loop also have the following parameters
- Initial Setpoint

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Default Level of the setpoint if the digital input

Mode Initial Setpoints
Excitation ON is not active.
Auto 100% (configurable)
Auto, Manual and Open Loop initial setpoints Manual 0% (configurable)
can be configured. Open Loop 0% (configurable)
PF 1.0
Var 0%
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. This allows surge-free switching between operating modes if the
new setpoint is within the setpoint limit.
Regulator Tuning
Auto (voltage control)
- Proportional gain Proportional Gain Vp Gain

[p.u.]
- Derivative time Derivation Time Tb [s]

constant 4 Vp
Vp
- Integral time Integration Time Ta [s]
constant
1/Ta 1/Tb 1257 [rad/s]
Compensation or Droop Kq [%] Machine voltage

droop [%] nsation Kq= 20% (max. compensation)
Compe
Kq= 0.00 (no effect)
Droop Kq= -20% (max. droop)
Reactive current
[%]
The second droop setting can be selected by digital input or over Modbus. Droop setting can be
selected on active power as well.
PF or Var Control Proportional Gain Vp P [W] Active power

underexcited overexcited
and PQ Limiter Derivation Time Tb [s]*) Var
Integration Time Ta [s] PF Generator PF
*) Only one parameter, see

voltage control Reactive power
Q- Q+ [var]
Motor

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Indirect PF or VAR Indirect PF/VAR enable  PF or VAR controller can be configured for
control direct or indirect control
In case of indirect control the PF/VAR is
regulated by increasing and decreasing the
voltage setpoint with a defined ramp rate for
AUTO mode.
Dead band of Q reg [%] Voltage SP is only changed when an error

of the VAR/PF regulator is higher than the
defined dead band.
Note: In PF mode the PF SP is calculated to
VAR SP.
On Delay [sec] On Delay will define the reaction time of the

indirect regulator. If the network voltage
changes, the voltage SP is changed after a
defined delay time. If SP is changed no
delay is given.
AUTO Ramp rate [%/s] AUTO Ramp rate PF indirect will define
PF indirect ramp rate just in case indirect PF regulator
is active
Manual Proportional Gain Vp

Gain
Field current control and Integration Time Ta [s] [p.u.]
Ie Limiter
Vp
1/Ta 1257 [rad/s]
All parameters should be stored in the EEPROM non-volatile memory after they are
configured. Store to EEPROM can be done via CMT1000, Panel or Remote Access. For
more information refer to the appropriate sections.
Expert Tuning
Derivator gain Kb:
By default Kb is set to 3. This gives a derivator gain of 4 x Vp. The parameter can be set
between 1 and 50 which will give a derivator gain between 2 x and 51 x Vp.
Variable kceiling, Upower @ Noload:
In case of variable input voltage, UNITROL 1020 will adjust the kceiling factor
automatically by setting the parameter Upower @ Noload. The kceiling factor will be
adjusted depending on the Upower input. By default the Upower @ NoLoad is set to 0 V,
which will lead to fix kceiling.
Variable kceiling, Kc Freq Dep
In case of variable machine frequency, UNITROL 1020 will adjust the kceiling factor
automatically by checking the check box. The kceiling will be adjusted linear to the
measured frequency, where the nominal frequency is taken as base.
Max PWM when boosting
When this function is enabled, the AVR will apply 100% PWM during undervoltage.
Thresholds are defined by the boosting setting.

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3.4.2 Startup Functions
3.4.2.1 Soft Start and Line Charging
- Starting voltage : Start Level Machine voltage Initial Setpoint

[%] from Initial Setpoint [%] (Auto mode)
- Delay until ramp : Hold Time [s]
- Ramp time : Ramp Time [s]
- Start Frequency Machine Freq. [Hz] Start level
The final value of Soft Start ramp is the Initial [s]

Setpoint for Auto mode. For more information
refer to Chapter 3.4.1.6.2 Setpoint Setting for Hold time Ramp
the Regulator.
Gen CB Closed Status = active
A second set for Line Charging parameters is Trigger immediately the soft start
also available. Line Charging is enabled by
Digital Input
Blocking excitation until UM frequency reaches a predefined level (parameter

name: Start Frequency)
Excitation is switched on (Command via digital input or remote control) when the
machine frequency is higher than the start frequency threshold. The Soft Start time
starts after the internal Excitation ON command. When the machine frequency goes
below 10Hz for longer than 10 sec, excitation is blocked. Excitation is started with Soft
Start when the generator frequency goes above the start frequency again.
Note: Soft Start is available only in Auto mode.

There is no indication if Excitation ON is blocked or not.
In order to measure the correct frequency, the machine voltage must be

above 2%
3.4.2.2 Field Flashing
Machine voltage
- Off Level Off Level [%] [%]
Signal field flashing
Setting the Off Level to 0% disables field Field flashing off level
flashing. Soft start level
[s]
Excitation ON

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3.4.2.3 Boost / Voltage Relay
- Pick-up volt. to Threshold [%] Machine voltage

generate boost Excitation ON
Soft start
command Excitation ON
Voltage not active
drop
100%
- Time boost Hold Time [s]
output is active Hysteresis
Threshold
- Hysteresis for Hysteresis [%]
the reset of t
boost output Delayed [s]
Off Hold time
- Delayed OFF Delay time [s] Boost = 0 1 1 0 1 0

Voltage Relay= 1 0 1 0 1
- Boost on grid Check box Hold Time = Maximum active Boost Time
only
- Block boosting Check box
in case of PT
alarm
Boosting is disabled if “Block boosting in case of PT alarm” parameter is selected and any
of the following failures is detected.
Failures: a) Partial Loss of UM
b) Loss of UM
Current boost operation is canceled when either failure is detected
Detection of PT failures relies on Supervision functions (status, not latched), PT failures

will only be detected when the DCH SW option is enabled
Note that Voltage Relay operates independently of the status of Excitation ON.
3.4.2.4 Forcing PWM to maximum
In order to make boosting independent of PID settings, PWM output can be driven to the
maximum value in case of undervoltage detection. This function is enabled by the
parameter “Maximum PMW when Boosting”.
The function is parametrized by the normal boost setting and on off timing is also
considering actual SP.

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U measured
<
1 ≥1 Set
& PWM
< forcing
1
x & 15
2 5
Reset
3
4 > OND
+
1 + x
2 ≥1
>
2
IeMax active e
1 Boost - Threshold
2 Voltage setpoint: if AUTO, setpoint itself; if PF or VAR, followup used to generate AUTO setpoint
(1.3s delayed voltage measurement)
3 Boost - Delayed OFF
4 Boost - Hysteresis
5 Boost - Checkbox «Enable PWM forcing»
Boosting is disabled if the “Block boosting in case of of PT alarm” parameter is selected

and any of the following failures is detected.
Failures: a) Partial Loss of UM
b) Loss of UM
Current boost operation is canceled when either failure is detected
Detection of PT failures relies on Supervision functions (status, not latched), PT failures

will only be detected when the DCH SW option is enabled
3.4.2.5 FRT Detection (Fault Ride Through)
FRT detection is a very fast detection of voltage dips as it is defined by grid code
requirements. The output is used to give a fast indication to the governor control in order
to remove active power. This will prevent the generator to trip because of speeding up.
The output is only activated in case the active Power is over the configurable power
threshold.
The reaction time depends on the configured voltage measurement
 3-phase measurement 20ms
 1-phase measurement 50ms

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Machine voltage
Excitation ON
- Voltage level to Low Level [%]
Voltage drop
generate FRT
100%
detection
- Voltage release level High Level [%]

High Level
to reset FRT
detection Low Level
t
- Power Threshold to Power Thr. [%] [s]
enable FRT FRT detection = 0 1 0
detection
Remark:
If FRT_HighThreshold < FRT_LowThreshold, then the output signal is switched off when
UM > (Low Threshold + 2%)
Therefore, High Level cannot be set below low level
3.4.2.6 Voltage Matching (VM)
Voltage Matching is a function from the Synchronization software (Chapter 3.4.2.7) but
included in the AVR basic software package. When Voltage Matching is activated, the
generator voltage setpoint is adjusted to match UM with UNET, also during
Synchronization; however there is no Fbias output. More information about Voltage
Matching can be found in Chapter 3.4.2.7 - Synchronization (SYNC).
3.4.2.7 Synchronization (SYNC)
The automatic synchronization of a synchronous machine with the Line is achieved using
the optional integrated synchronizing function. By setting a few simple parameters,
UNITROL 1020 supplies the corresponding control signals for the speed governor and
closes the circuit breaker.
Analog speed correction Fbias is given out from the UNITROL 1020 analog output to the
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 1020 will drive the speed close to actual network frequency.
As an alternative, UNITROL 1020 supports digital increase / decrease signals towards
the governor control.

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UNET
Setpoint fSP = fNom Synchrocheck
Command
CB
Fbias Sync
Speed Controller
Setpoint
UM
Regulator
T SM E
Figure 3-8 Typical application for Synchronization.
CAUTION!
Synchronization should never be performed by calculation only. All
measurements shall be confirmed on site before synchronization takes
place.
The power circuit breaker (CB) must not be closed unless both
voltages are at least approximately synchronous (coincident).
Otherwise, this may result in faulty line operation, loading of the
synchronous machine and, in extreme cases, damage to the
synchronous machine.
A separate synchrocheck relay might be used to secure the right
operation. For further information please contact ABB.
Measuring and Matching
The values are obtained by the two measurement signals UNET and UM
 Voltage difference (amplitude)
 Slip (frequency difference)
 Phase-angle difference
The voltage matching function gives the adjusting value to the internal voltage regulator
and the frequency matching function sends the analog signal Fbias to the turbine
regulator.
Monitoring and command generation
The command to close the breaker (CB) is released if all conditions are fulfilled.

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Description of parameters:
Min Slip [Hz] : Minimum Slip (Delta U) UNET - UM [%]

Max Slip [Hz] : Maximum Slip 10.0
Max DeltaU[%] : Max. voltage difference 5.0
Slip
Note: fM > fNET
Slip always negative [Hz]
-5.0
-10.0
-1.00 -0.40 0
Maximum Minimum
Angle = 10 -10
0
20 -20
Max Delta Angle Max Delta Angle [deg] 40 -20 -40
60 -60
[deg]
80 -80
Tot CB CloseTime Time between closing command and closed breaker (see data
[ms] sheet of the breaker).
Voltage Offset [%] Voltage correction factor between UM and UNET.

UNET USED = UMEASURED FROM NET + Voltage Offset
Voltage Offset is provided in the current software release for

backwards compatibility with earlier versions.
Note 1: Voltage correction can be achieved by modifying the

Network PT parameters.
Note 2: Because Voltage Offset functions independently of other
functions, it’s recommended to leave Voltage Offset = 0 when
correcting voltage using the Network PT settings.
Angle Offset [deg] Phase correction factor between UM and UNET. Delta angle is
calculated as follows:
Delta Angle = PhaseNET – PhaseM + Angle Offset
Example
Situation: Due to a step-up transformer between machine and
grid, UNET is delayed 30º with respect to UM.
Correction needed: Angle Offset = + 30º (positive).

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SYNC When set to False (default), this enables the monitoring of Gen
DisableCBCheck CB Closed Status input during Synchronization (only): if Gen CB
[True / False] Closed Status is active, Voltage Matching is not performed.
When set to True, this disables the monitoring of Gen CB Closed
Status during Synchronization (only): Voltage Matching is
performed disregarding the Gen CB Closed Status input (not
recommended in most applications).
Important: This parameter must be configured to False for
backwards compatibility with releases 4.401 or earlier.
IMPORTANT!
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.
Examples
[%] Setpoint AUTO
Voltage matcher 110 Maximum
The machine voltage is raised to the level of UNET
103
the line voltage. Ramp = constant
100
Ramp Rate has to be adjusted in the menu UM
98
Setpoint AUTO Minimum
90
[Hz] Fbias
+1
Frequency matcher +0.2
fNOM = 50 Hz (45 Hz < fNET ≤ 54 Hz, 50 Hz) -1
(54 Hz < fNET < 66 Hz, 60 Hz)
fNET = 49 Hz
[Hz]
fM = 50 Hz 50 fNOM
fSP = 50 Hz (Setpoint speed governor) 49.2
Slipmax = -0.4 Hz 49
+0.2
fNET
Slipmin = 0 Hz
Fbias =
fNET – fNOM – (SlipMAX – SlipMIN)/2- SlipMIN = -0.8 Hz
fSP+Fbias = 49.2 Hz
Using digital output signals to adjust the speed:
As an alternative to the fbias signal, UNITROL 1020 also supports increase and decrease
signals as digital outputs in order to adjust the speed. The digital outputs are pulse width
modulated with 4000 ms base time. The more the machine frequency matches the
network frequency, the shorter the pulses are.

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Maximum Minimum
-0.40 0.00
Max Max Max (configurable) (configurable) Min Min Min
-5.00 -1.0 -0.50 +0.50 +1.00 +5.00
Slip
[Hz]
50%
2000 ms
1000 ms
2000 ms
1000 ms
200 ms
100 ms
200 ms
400 ms
400 ms
100 ms
Pulse
0 ms
width
Dead Bus Synchronization
UNITROL 1020 supports synchronization to a dead bus (Unet < 10%). To enable dead
bus synchronization, the digital input “Sync Dead Bus enable” must be configured and
applied.
The digital input should be wired over the MCB of the Unet PT protection in order to
ensure that Unet is < 10%.
WARNING!
! In case of broken or open Unet PT measurement, the machine might be

seriously damaged when applying dead bus synchronization
Preconditions for Synchronization
Unet Sync dead Output behavior

bus enable
<10% 1 CB close command and Synchrocheck output is applied
after the network voltage is below 10% for 2 sec.
Voltage matching and control signal to the governor are
disabled
10% …50% any Synchronization and Synchrocheck is blocked
Voltage matching and control signal to the governor are
disabled
>50% any CB close command and Synchrocheck output is applied.
Control signals to the governor are applied
Activation:
The Synchronization can be activated via digital input or Remote Access. For more
information refer to Chapter 3.3.5 Digital Inputs, Chapter 3.4.6 Modbus for Remote
Access and 6.4.5 Menu Structure of CMT1000.
The Synchronization and Voltage Matching are features that are activated using the
same activation signal, called Synchronize. When the Synchronization SW is not
available in the AVR (i.e. LED off in SW-options window of CMT1000), only Voltage
Matching will be activated when Synchronize digital input is set to high. On the other
hand, when Synchronization SW is available (i.e. LED on in the SW-options window of
CMT1000), Synchronize input will fully activate the Synchronization feature, which also
includes the capability of voltage matching and the Fbias output. For more information
about Voltage Matching see Chapter 3.4.2.6 Voltage Matching (VM).

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3.4.2.8 Start sequence with dead bus synchronization
With regard to support dead bus synchronisation and line charging in combination,
UNITROL 1020 provides a special start sequence.
In case digital input Sync Dead Bus Enable is active, Excitation On and Line Charging
are enabled, the soft start ramp (Internal Excitation ON status) is started after the
generator breaker is closed. Generating the close command of the generator breaker is
only applied if SYNC is enabled.
3.4.3 On-line Operation Functions
3.4.3.1 Voltage Droop Compensation (VDC)
For island operation only
UNITROL 1020 offers a special feature called Voltage Droop Compensation or VDC. This
feature equally shares the amount of reactive power between generators connected in
parallel to the same bus by using the RS485 bus for communication between AVRs.
During VDC mode all AVRs operate in Auto mode with a voltage droop control. Each
AVR sends the value of its own amount of reactive power over the RS-485 bus, while the
other AVRs take this information to calculate a common average MVAR setpoint and
compensate the effect of the voltage droop. The setpoints are calculated to maintain the
voltage level on the busbar at 100% (not adjustable).
The AVRs that are considered to calculate the common average MVAR can be selected:
A) All units which are connected to the busbar, only dependent on the GCB status
B) All units working in VDC mode
In order to get a smooth transition between any mode and VDC mode the load sharing is
activated over a ramp time. The ramp time defines the time after switching on VDC mode
until VAR on all machines is equalized.
Machine voltage
100
Reactive current
Var SPmax [%]

Var SPmin
Important:
The Compensation Droop Kq shall be set at -5% (negative value) if VDC mode is used.
The voltage is kept at 100% Um inside the VAR SP min/max. If VAR is outside this range
the voltage will be adjusted according to the set droop (Kq).
VDC Mode will keep the bus voltage at 100% within the Var Setpoint min and max limits.

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NOTICE!
Load sharing will only be accurate in case of matched PTs. Voltage
must be matched to a single reference with 0.1% accuracy
Voltage droop compensation can be used for two different bus configurations.
a) Busbar configuration with 2 breakers
b) Ring structure with up to 8 segments
The load sharing takes place only in machines that are connected directly and
automatically controlled by digital inputs that give information about the breaker.
Common parameters for VDC:

Network Connection Type Busbar or Ring
RS485 error forces to AUTO mode False / True
VDC Ramp Time 0.1 – 60.0 sec
Baud Rate 59.7k / 57.6k
Calc ref from AVRs in VDC mode only False / True
Communication over RS485 between the parallel units:
Each AVR has to be configured with a unique AVR-ID number which identifies itself
among the others on the bus.
The VDC communication refers to the data transmitted over the RS485 bus whereas the
VDC operating mode refers to whether this data is used for compensation of the reactive
power or not. The AVR enables the VDC communication (i.e. transmit data over the bus)
as soon as the "Gen CB Closed status" input is active (logical one) in case bus bar
configuration is selected and VDC software is available in the device except during
Standby or when Remote Access via the RS485 is active. When Ring structure is
selected all AVRs will transmit their information on the bus. As long as the AVR is in
Standby or as long as Remote Access via RS485 is active, the VDC communication is
disabled and will not be transmitted over the bus. Once the VDC communication is
enabled, the data available on the bus is taken and used for the regulation. This is only
possible when the AVR is switched to VDC operating mode (i.e. by VDC Enable digital
input).
The availability of the VDC communication disregarding the operation mode (even during
Excitation Off) allows the cabling connections and communication quality to be easily
tested. The testing is performed by forcing the "Gen CB Closed status" input signal and
by monitoring the status of the communication using the VDC Monitor tool included in the
CMT1000. For more information about VDC Monitor refer to Chapter 6.4.7
Communication Menu.
The wiring connections of the RS485 bus are explained in Chapter 3.3.9.3 RS485
Interface.
3.4.3.2 Voltage Droop Compensation for busbar configuration
The VDC software allows the network to be divided into smaller entities. Each AVR can
operate in one of three pre-determined island grids called Primary and Secondary Nets.
The Primary Net (open breaker) is selected by default if the Secondary is not configured.

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Load A Load B Load C
RS-485 RS-485 RS-485
AVR 1 AVR 2 SM AVR 3 SM AVR 4 SM AVR 5 SM AVR 6

SM SM
Figure 3-9 VDC application example of six machines and two nets.
When the Secondary Net is required, it should be configured using a digital input. This
input determines whether the AVR uses data for VDC calculation from the devices
configured in the Primary or Secondary Net. The user can select 4 different net IDs
depending on two digital inputs. The load sharing takes place between AVRs with the
same net IDs. The list below shows an example of how to set the net IDs for each AVR in
relation to the digital input.
Net type Net ID Digital input AVR 1+2 AVR 3+4 AVR 5+6
default Secondary Net 1 Net ID Net ID Net ID
Secondary Net 2
Net 2 Net 1
Primary Net 1 0 0 11 12 13
Secondary Net 2 0 1 2 2 13
Note that the net IDs are chosen in a way to represent the possible load sharings:
 Net ID1: Load sharing only in the same bus segment
 Net ID 2: Load sharing between Load A and B
 Net ID 3: Load sharing between Load B and C
 Net ID 4: Load sharing between all machines
The Primary and Secondary Net ID numbers should be different from each other and
unique for each load sharing group.
When no digital input is configured for Secondary Net 1 nor Net 2, the VDC net ID is set
to the primary net ID.
3.4.3.3 Voltage Droop Compensation for Ring Configuration
VDC mode can also be used in a ring structure, where the ring can be split up and the
AVR automatically shares load with the connected machines.
A ring is based on segments with a left (decreasing) and right (increasing) breaker. The

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number of machines inside a segment is not limited. Only the maximum number of total
machines is limited to 31.
The status of the breakers must be wired to digital input (Secondary Net 1 and
Secondary Net 2) of the AVR.
Where Secondary Net 2 is used for the left side (decreasing) breaker and Secondary Net
1 is used for the right side (increasing) breaker.
AVR 1 AVR 2
SM SM
Ring segment, terminated by left and right side breaker
Note that the net IDs are equal to the bus segment where the AVR is connected to. The
AVR status gives an indication of two different island operations.
 Primary Net One of the section breakers is open
 Secondary Net Both section breakers are closed
A ring structure is built with up to 8 segments; see the example for 3 segments below.
Segment 1 Segment 2 Segment 3
SM SM SM SM SM SM
Ring segment, terminated by left Ring segment, terminated by left Ring segment, terminated by left
and right side breaker and right side breaker and right side breaker
The auxiliary contact of the breaker must be wired only inside the segment. In order to
select the correct machines regarding the load sharing, all AVRs give the information of
the segment breaker and their own position (segment number) over the RS485 bus to all
other AVRs. This enables the system to detect wrong configuration which is indicated as
“VDC Ring Error”.
In addition the user can select the common section breaker, where a combination of two
breakers in series is routed to neighboring sections. This will ensure correct load sharing
even if one segment is completely powered off.

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If there is neither left nor right side breaker, the corresponding digital input (Secondary
Net1 / 2) must be forced to logical 1.
Each AVR is collecting all status information of the ring tie breakers over the RS485 bus
in order to select the correct load sharing group. In case of a separated segment the load
sharing takes place on the remaining ones and separately on the isolated segment.
3.4.4 Limiters and Monitor Functions
3.4.4.1 Limiters
V/Hz Limiter Machine voltage

[%]
- V/Hz knee point frequency fknee [Hz] 100
- Slope Slope [%/fk]
(diff between fknee and
0Hz) [Hz]
fknee
In case of a short circuit at the machine terminals, the frequency is calculated out of the
machine current. This guarantees a correct functioning of the V/Hz limiter in any
condition.
During soft start the V/Hz limiter minimum output is limited to 5%
Sudden AUTO SP drop

at frequency drop Machine Frequency
[Hz]
50
- Freq. drop threshold V/Hz Fdrop [Hz] V/Hz drop
- Freq. drop time span V/Hz MeasDe [ms]
V/Hz MeasDealy
Time [s]
- AUTO SP drop V/Hz Udrop [%]

- SP hold time V/Hz Hold [sec] AUTO SP
[%]
- SP recovery time V/Hz Recov. [sec]
100
V/Hz Udrop
V/Hz Hold V/Hz Recovery
Time [s]
The function is blocked:

 During Soft Start
 When PQ Limiter is active
 When Voltage Relay is active
 When Generator state is “no load” or “Parallel with grid”

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Used for heavy load applications in island operation to unload the engine in order to
recover faster to nominal speed.
Ie Minimum current limiter P [W] Active power

underexcited overexcited
- Minimum limit Minimum [%] Limiter-
characteristics GENERATOR
- Limiter active Active = True/False
Iemin Reactive power
Q- Q+ [var]
UM2
MOTOR
Xq
Ie Maximum current limiter Excitation current

- 1st limit Maximum [%] [%]
1st limit
- Hold time Maximum Hold Time [s]
2nd limit
- 2nd limit delay Delayed [%] Contin. current
- Hold time Delayed Hold Time [s]
- Continuous current Hold time Hold time
[s]
Limiter active Continuous [%]
Active = True/False
Cool-down behavior
In case Ie Limiter is hit short after Ie Limiter was released, the 1st limit hold time will be
reduced in order not to overheat the winding, where the reduction of Limiter times is
depending on the time Ie actual was running below 100%.
PQ Limiter P [W] Active power

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

Reactive power
Q- Q+ [var]
P=50%
Motor
- Voltage dependency
active Volt.Dependency:True/False P=100%
- Limiter active Active = True/False
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
- With active limiter, AUTO SP is taken from the FRT AUTO SP Hold enable =
operation point prior to fault condition True/False

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IM Limiter
- Limiting value of the maximum machine current Maximum [%]
- Time Multiplier according to IEC 60255-3, Table 1,
Col. B, very inversed characteristic Time Multiplier K
- Limiter active Maximum Active = True/False
Limiter becomes active after time set by
„very inverse characteristic“
13.5
t= ∗𝐾
Im
−1
𝐼LIM
3.4.4.2 Limiters Temperature Influence
IM Limiter
Machine current IM
[%]
T1 at Max IM T1 [°]
Max IM P1
T2 at IM th2 T2 [°]
T3 at IM th3 T3 [°] Im_th2 P2
T4 at IM th4 T4 [°] Im_th3 P3
Machine current level IM th2[%]
25
Machine current level IM th3[%] P4 Cooling temp.
20 40 T1 T2 T3 T4 100 [°]
Ie Limiter Excitation current Ie [%]
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 th4 T4 [°] Ie_th3 P3
25
Excitation current level Ie th2 [%] P4 Cooling temp.
Excitation current level Ie th3 [%] 20 40 T1 T2 T3 T4 100 [°]
3.4.4.3 Field Voltage Limiter
The measured excitation current is used to estimate the field voltage through a look-up
table, in which the values are linearly interpolated. If the estimated field voltage is larger
than the defined maximum field voltage (Ufmax), the difference is multiplied with the gain
UfLimGain. The resulting value subtracts the maximum excitation current limit Max Ie,
thus reducing the field voltage.
If the gain UfLimGain is set to zero, this limiter is disabled.
Gain Ie_Max
Ie_Max-Ie_Del +
Look-up Vfd + error - Ie_Max value –
Ie  p  to Ie_Max limiter
table
- 0
Vfd_max

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Look-up table Uf, Rotor voltage [%]
Uf@Ie 400%
Uf@Ie100% Vf [%] Uf@Ie 300%
Uf@Ie 200%
Uf@Ie200% Vf [%] Uf@Ie 100%
Uf@Ie300% Vf [%]
Uf@Ie400% Vf [%] 100% 400% Ie [%]
Ufmax Vf [%]
UfLimGain [n]
To set this parameter, refer to 6.4.8 Tune Menu.
3.4.4.4 Double Channel (DCH)
Double Channel (DCH) is an optional feature that integrates supervision or monitor

functions and redundant channel support to build robust and flexible double channel
systems.
The SW-feature is also used for single channel systems in order to force the system into
Manual mode or trip excitation.
Overview
The Double Channel feature has the following main components (Figure 3-10):
1. DCH Supervision / Monitor

The Double Channel Supervision is a feature with 23 supervision functions that
can be used to trigger two Alarms and/or a Trip output from the AVR. The
configuration is performed using a so-called Configuration Matrix.
In addition, 10 monitor functions can be configured in order to control 2 Monitor
Alarm outputs. The monitor Alarm outputs can also be routed to the Supervision
alarm and trip outputs.
With the configuration matrix the customer can define up to 5 independent digital
output signals.
2. Redundant Channel support

Channel changeover, DCH Follow-up and DCH communication
The Channel Changeover is a feature used to transfer the control to the other
channel; normally used when the active channel trips or under special
circumstances (i.e. monitoring alarms) that can be configured in the AVR.
The DCH Follow-Up is a function which is active as long as the AVR is in Standby
mode (i.e. not active), monitoring the setpoint used on the other channel in order
to be ready to takeover in case of changeover. The DCH Follow-up is different
from the Follow-up used to change between operation modes within the same
AVR. For more information see Chapter 3.4.4.4.8 - DCH Follow-Up.
The communication with the second channel is made using the CAN interface and
is called DCH Communication. Throughout the CAN bus, measurements, statuses
and setpoints are transmitted and received from both channels. The data
information can be read from Panel, CMT1000, using Remote Access and is used

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for the channel changeover functionality.
The features included in the Redundant Channel support (channel changeover,

follow-up and communication) are in operation and active as long as the DCH
CAN communication is enabled and error-free. However, DCH Supervision can be
used independently of the existence of a second channel, and is therefore also
suitable for single channel applications. DCH Supervision does not depend on the
DCH CAN communication.
The Double Channel software must be available in the AVR (i.e. unblocked)
before the use of DCH Supervision and/or functions from Redundant Channel
support. Otherwise the configuration is not possible and Alarm, Trip and
Changeover digital output are unconditionally set to logical zero (i.e. not active).
The schema in Figure 3-10 shows the relationship between the main functions
described.
DCH Supervision
Configuration Matrix
Status
(Latch)
Supervision 2
Functions
(19) 3
Alarm 1 assignation
Alarm 2 assignation
. .
Trip assignation
. .
. .
Monitor 20
Functions
(8) 21
Standby
Trip status config
Standby to DO
Alarm 1 status config port
Standby
Alarm 2 status config
Redundant Channel support

Channel Changeover
DCH Follow-up (block not shown)
DCH Communication
2nd Channel Alarm 1
2nd Channel Trip Channel

to DO
Changeover Changeover status
port
Comm Status Logic
DCH CAN communication data flow

to 2nd
Measurements, setpoint and
Measurement &
channel
other data used by DCH Communication
Follow-Up and user interfaces
Figure 3-10 Schema of main Double Channel functions.

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DCH Supervision Functions
The DCH Supervision has a total of 23 status signals from different supervision functions.
It also has two Monitor Alarm outputs that can be configured to generate a (global) Alarm
and/or a (global) Trip. As shown in Figure 3-11, Alarm and Trip status signals are
configured by a so called Configuration Matrix. Alarm and Trip are independent of each
other and they can be configured differently.
The Configuration Matrix allows the user to select which monitoring function will produce
an Alarm and/or a Trip at the output of the Supervision function. For instance, as soon as
a monitoring function, which is configured to produce an Alarm, reports a failure, the
Alarm status at the output of the Configuration Matrix will be set to active (logical true).
The same could happen to the Trip status if the monitoring function is configured to
produce a Trip. The configuration of Alarm and Trip is handled independently of each
other and therefore it provides great flexibility when engineering a project-specific
system.
Each monitoring function that can be configured in the Configuration Matrix has a status
which is used to detect the failure and triggers Alarm and/or Trip according to the
configuration. The status from each monitoring function is implemented with a latch
memory which makes the value remain active (logical true) even after the failure has
been diminished and the monitoring function no longer reports a failure. Therefore, it is
possible to determine which monitoring function causes an Alarm or Trip even after de-
exciting the machine. The latch memory of all monitoring function statuses can be
cleared by the digital input "Reset Alarm" (only if the failure has already been diminished)
or by powering off the device (Figure 3-11).
DCH Supervision
Configuration Matrix
Status Suppervission
(Latch)
1
Suppervission
Functions 2
(19)
3
. .
Alarm assignation
Alarm assignation
Trip assignation
Reset
Reset clears (to Logic 0) each . .
latched status only when the one
from the monitoring function is
. .
already Off or Logic 0.
Monitor 20 Trip and Alarm status Alarm and Trip may be

Functions may be monitored from configured to output or
21 the user interfaces not its status during the
(8)
Channel is in Standby
Standby
Trip status
Each status signal is latched config
when it goes to On or Logic 1 Standby
Alarm status to DO
( edge detection ) config port
Standby
Alarm status config
Figure 3-11 Double Channel Supervision.

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Both Alarm and Trip statuses are the outputs from the Configuration Matrix and they can
be monitored using the CMT1000 and Remote Access. Alarm and Trip Status can be
configured as digital outputs (DO), however as shown in Figure 3-11, they are not directly
connected to the output. Instead they are connected to the Standby Configuration boxes.
The Standby Configuration boxes, shown in Figure 3-11, prevent Alarm and Trip to
output their status values to the DO port during Standby mode; and this function can be
used to prevent undesired alarms as long as the Channel is in Standby. When the
Standby Configuration blocks the status of Alarm and/or Trip, the value transferred to the
DO port is logical zero.
A list with all the DCH monitoring functions (12) is shown in Table 3-1. Following, Table
3-2 shows the 5 status signals from other UN1020 functions which can also be
configured with the Configuration Matrix.
Table 3-1 Double Channel Supervision functions.

Supervision Description Detection
Function Time
SW real time error The SW is not running within time frames or the real-time 200ms
On CMT1000: system
"Watchdog" Failure condition: Controller overload
Supervision of MODBUS keep alive Remote Access
MODBUS Comm. Alarm
feature. Active independent of “remote access” is granted.
On CMT1000: "Loss of 1 sec.
Supervision function is only reset in case new
Remote Control".
communication is established by toggling the keep-alive bit.
Machine Voltage Machine PT monitoring function for 3-phase system only. 30 msec.
One or Two phases lost
Failure condition: Error is detected if U0 sum is over 70%
On CMT1000: of Unom.
"Partial Loss of UM"
Machine Voltage Machine PT monitoring function. The function is activated 60 msec.
only after the Soft start is finished.
Loss of all phases
Failure condition: Excitation current is higher than 80% of
On CMT1000: No-Load and Machine Voltage falls below 10%. Monitor
function is triggered only when no short-circuit condition is
"Loss of UM"
detected.
Short circuit is detected when voltage falls below 10% and
machine current jumps up more than 100% within 50ms.
The monitor functions can only be reset in case UM>15%
and Ie>50% of No Load
Machine current monitor Machine CT monitoring function 60 msec.
On CMT100: Failure condition: Machine current is below 2% and
“Loss of CT” machine voltage is between 90% and 110% and excitation
current is out of the range of 50% to 150% of noload
excitation current.
The supervision function is blocked in Standby mode.
Machine Voltage Freeze Monitoring of the electronics for the Machine voltage 60 msec.
monitoring measurement components on the PCB (this is not a PT
Phase L1 monitoring function).
Phase L2 Failure condition: The voltage measurement is more than
Phase L3 10%, constant and not alternating.
On CMT100:
“UMLx Freeze”

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Function Time
Network Freeze Monitoring of the electronics for the Network voltage 60 msec.
monitoring measurement components on the PCB (this is not a PT
On CMT100: monitoring function).
“Unet Freeze” Failure condition: The voltage measurement is more than
10%, constant and not alternating.
Machine Current Freeze Monitoring of the electronics for the Machine current 60 msec.
monitoring measurement components on the PCB (this is not a CT
monitoring function).
On CMT1000: Failure condition: The current measurement is more than
"IM2 Freeze" 10%, constant and not alternating.
Loss of control Supervision of PWM control 500 msec.
Failure condition: Excitation is On, PWM stays below
On CMT1000: 12.5% of 1/Kceiling and excitation current is above 250%
"Loss of control”" compared to No Load condition.
Function is blocked when “Voltage Relay” is active
Loss of Excitation Supervision of Excitation current 500 msec.
Failure condition: Excitation current is less than 50% of
On CMT1000: the specified value of No-Load condition or Upwr is less
"Loss of Excitation”" than 10V and PWM is above 2/Kceiling.
(Ie < 50% OR Upwr < 10V) AND PWM > 2/Kceiling
This function is disabled in standby mode.
Function is blocked when “Voltage Relay” is active or at

switchover (standby channel becomes active) for 5 sec.
The time blocking can be disabled in the expert window.
Temperature Supervision of controller temperature 2 sec.
Level 1 Failure condition: Temperature is equal to or above 70
On CMT1000:
"Temperature Limit 70°C”"
ºC.
Temperature Supervision of controller temperature 2 sec.
Level 2 Failure condition: Temperature is equal to or above 85
On CMT1000:
"Temperature Limit 85°C”"
ºC.
External Alarm Supervision of external digital input signal (must be 100 msec.
On CMT1000: assigned in the digital input section).
“External Alarm” Failure condition: The digital input value is copied to the
status of this function.
RS 485 communication Communication supervision based on bad frames rates 10 / 2 sec
monitor Failure condition:
On CMT1000: Modbus: 10 bad frames in 10 sec
“RS485 Bad Frames”
VDC: 10 bad frames in 2 sec
VDC breaker error Mismatch of breaker detection for busbar configuration or 1 sec
On CMT1000: in the same section for VDC ring configuration
“VDC Breaker Status Error ” Failure condition: The same breaker will show up with a
different status

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Function Time
Internal Power supply Supervision of all internal power supply 10 msec
monitor Failure conditions: According to HW design
On CMT1000:
“Internal Power Fail”
Digital output supervision Digital output and 24 V power supply supervision 10 msec
on CMT1000: Failure condition: Digital output current per pin exceeded
“Digital Output Fail” 500 mA or 24 V output voltage goes below 12 V dc
CAN communication Supervision of communication in case a double channel 1 sec
supervision setup is used. The following conditions must be fulfilled in
on CMT1000: order that supervision is active:
“CAN Monitor” - Double channel communication must be enabled
(checkbox in monitor and protection window)
- SWO Startup Hold time must be >0
The supervision becomes active after the startup hold time
is expired and no data can be sent / received any more.
Monitor Alarm 1 Configured monitor Alarm 1
DCH Monitor Functions

Table 3-2 Monitor function statuses that can be configured with the Configuration Matrix.
Detection
Monitor Functions Description
Time
FCB Alarm Supervision of Field Circuit Breaker. 1 sec.
Rotating diode monitoring alarm.
Diode Alarm configurable
Requires RDM software (optional).
Supervision of diode monitoring trip status.
Diode Trip configurable
Requires RDM software (optional).
Generator Overvoltage Configurable overvoltage monitor configurable
Configurable undervoltage monitor
Generator Undervoltage configurable
Will be activated after soft start is finished
Excitation Overcurrent Configurable overcurrent monitor configurable
Excitation Overvoltage Configurable overvoltage monitor configurable
Upwr Overvoltage Configurable overvoltage monitor of excitation power configurable
Supervision of external digital input signal (must be
External Alarm 100 msec.
assigned in the digital input section).
Emergency Exc. OFF Emergency Exc. Off Command latch 5 msec.
Supervision of relative power (Prel)
Reverse Power Negative threshold is used for generator mode Configurable
Positive threshold is used for motor operation
Alarm is triggered in case GCB cannot be closed by the
GCB Alarm close command within 2 sec or machine current exceeds 2 sec
20% with open GCB status
AVR output SC AVR output short-circuit detection 10 ms
Sum of configurable Limiter status
Limiter Monitor 1 na
(Configurable in ‘Limiter Monitor’ Window)
Sum of configurable Limiter status
Limiter Monitor 2 na
(Configurable in ‘Limiter Monitor’ Window)

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Alarm output toggling
Supervision and monitor alarms can be assigned for digital outputs as a summary alarm.
If a single monitor function is triggered, the output becomes active and the status is
latched.
The user can activate the toggling function by means of a parameter if the monitor
function detects a new alarm again. In this case the digital output linked to the alarm will
be deactivated for 1 sec (toggled off) and reactivated again (toggled on).
Channel Changeover Logic
As shown in Figure 3-12, the Changeover status is the output of the AND-gate which
depends on the Alarm and Trip Status from the current channel, Alarm and Trip Status
from the Second Channel and the DCH Communication Status which is an indication of
the communication quality between both channels.
The DCH Communication refers to the data transmitted over CAN between both
channels, and it contains setpoint information, measurements, status signals (including
Alarm and Trip) and others. The status of this communication is logical one (good) if data
coming from the Double Channel feature is received well and free of errors (CRC check).
On the other hand, the Communication Status is logical zero (bad) if the received data
contained errors, the communication was not enabled (no data received) and/or the
configuration was not set properly. Alarm and Trip from the Second Channel should be
configured using the DCH Supervision in the other channel.
To increase the flexibility, the Changeover dependency on Alarm and Trip status is
configurable; i.e. checkboxes allowing to configure whether these signals are part of the
AND and OR gate inputs of the logic decision (Figure 3-12). Each checkbox output is
determined according to the rules shown in Figure 3-13. An important setting is the
checkbox connected to the DCH Communication Status, which additionally lets the signal
pass through until the input of the AND gate. It also enables the DCH Communication
over CAN. The DCH Communication should be enabled to use the Changeover
functionality; otherwise the Changeover Status will be zero all the time (see Figure 3-12
and Figure 3-13).
The decision logic from Figure 3-12 shows that once the DCH Communication is
enabled, the dependency of Changeover Status is defined according to the checkbox
configuration and the Alarm and Trip status from both channels. When, for instance, the
checkboxes are configured according to Figure 3-12, the Changeover Status will be
logical one when: the Trip Status from the current channel is equal to one, the Trip Status
from the Second Channel is equal to zero (i.e. no trip in the Second Channel and it is
ready to takeover) and the Communication Status is equal to one (data from the Second
Channel is being received correctly).
The Changeover status value is latched (retains the value) when the AND gate output
changes from zero-to-one. The latched value may be cleared (to zero) using the Reset
command only if the output of the AND gate is already zero as well.
The Changeover status can be assigned to a digital output signal from the AVR. When
compared with Alarm and Trip DO signals, the DO assigned for Changeover always
outputs the Changeover Status disregarding whether the channel is Standby or Active;
for Changeover DO, this cannot be configured as it is for Alarm and Trip.

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Changeover Logic
Alarm 1 status
Alarm 2 status OR
Trip status
2nd. Channel Alarm 1 to DO

AND Changeover status
port
OR
2nd. Channel Trip
Changeover status is latched

DCH Comm. Status when it goes from zero-to-one
(edge detection)
Reset
Enable DCH Communication
Clears (to zero) the latched
when
Changeover status only if
the AND output is also zero.
DCH CAN communication data flow

to second
Measurement &
channel
Communication
2nd. Channel measurements & Status

Measurements & Status and will not be available if DCH Comm. is
Setpoints for DCH Follow-Up not enabled or if DCH Comm. Status
and user interfaces Ok is equal to zero (i.e. bad quality).
Figure 3-12 Channel Changeover logic and configuration.
Check box for Alarm & Trip (also 2nd. Channel)

A A
A 0 (logic)
Check box for DCH communication
AND AND
A A A 0
1 (enable) 0 (disable)
DCH DCH
Measurement & Measurement &
Communication Communication
Figure 3-13 Configuration checkboxes rules.
The Changeover output is intended to be used together with the Standby input, in order
to activate the Redundant channel and deactivate the Main one. The Standby status can
be set via Remote Access or via a digital input (common case). Figure 3-14 shows a
typical example of Changeover output to set the Redundant Channel to Standby or Active
mode. The ResetAlarm input is normally used to clear the latch memory of Changeover

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output and bring the Main Channel back to Active (and the Redundant back to Standby)
once the failure has been diminished or fixed.
Main Channel Redundant Channel
DO - Changeover DI - Standby
DI - Standby
DI - ResetAlarm DI - ResetAlarm
CAN interface
Figure 3-14 Typical configuration of Changeover output
Delay on Switch Over output after Power Cycle

Switching back to channel 1 can be done by applying reset Alarm signal to Channel 1
AVR or by power cycling Channel 1.
In order to enable the correct setpoint follow up on Channel 1, the switch over output is
kept active for a defined delay time, configurable by the parameter SWO Startup Hold
Time, which allows Channel 1 to initialize all filters and statuses before taking over control
again.
Switchover hold time is normally only active in case of a power cycle. In terms of Modbus
communication setup, the hold time can also be enabled for regular switch back by setting
the checkbox “SWO Hold Time always active”.
Automatic Logic
Within the DCH SW a configurable logic for forcing the AVR into Manual or automatically
switching off excitation logic is provided.
Automatic forcing logic

Alarm 1 status
Manual ON
Alarm 2 status OR
Status
Manual ON
GCB Status
AND
Excitation ON
Trip AND
Status
Excitation ON
Figure 3-15 Automatic forcing logic
DCH Follow-Up
The DCH Follow-up is an automatic function that runs in the Standby channel, following
the actual setpoint used by the Active channel, in order to perform a bumpless transfer
during changeover. The DCH Follow-up is different from Channel Follow-up, which is
used to have bumpless changeover between operating modes within the same Channel
and could also be used on systems without Double Channel software support. For more
information about Channel Follow-up see Chapter 3.4.1.5 - Channel Follow-up.
The DCH Follow-up uses the setpoint information from the Active channel over the CAN

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interface. During DCH software operation, the Active channel sends the setpoints of the
current operation mode and the one for Manual mode through the CAN interface. These
two values are setpoints delayed and calculated out of the measurements of the Active
channel; the delaying method minimizes the influence of failures on the setpoint
calculation (e.g. wrong measurement due to PT failure) and improves the bumpless
characteristic at the moment of changeover.
At the moment of changeover, the Standby channel decides whether to take the setpoint
from the Active channel (over the CAN interface) or from its current measurements,
before it goes Active. The decision depends on the operation mode of both channels
according to the following:
 If operation modes on both channels are the same (except for OpenLoop), the
setpoint is taken from the Active channel, i.e. delayed setpoint over CAN.
 If the Standby channel has Manual mode enabled, the setpoint is taken from the
Active channel, i.e. delayed setpoint over CAN.
 If the Standby channel has Open Loop mode enabled, the setpoint after
changeover is set to zero.
 For all other possibilities not described above, the setpoint will be calculated from
the current measurements of the Standby channel; i.e. not from CAN. Under
these conditions, the setpoint is calculated based on delayed measurements from
the own channel; the delaying method minimizes the influence of failures on the
setpoint calculation and improves the bumpless characteristic.
A summary of the described cases is shown in Table 3-1

Table 3-3 Setpoint follow-up logic Note: SP = Setpoint.
Mode Standby AVR
Auto Manual PF VAR Openloop
Sync
VDC
Mode Auto Calculated Calculated

Manual SP
Sync Auto SP of from from
of Active SP = 0%
VDC Active AVR Standby AVR Standby AVR
AVR
Measurements Measurements
Active Manual Calculated Calculated Calculated
Manual SP
from from from
of Active SP = 0%
Standby AVR Standby AVR Standby AVR
AVR
Measurements Measurements Measurements
AVR PF Calculated Calculated
Manual SP
from PF SP of from
of Active SP = 0%
Standby AVR Active AVR Standby AVR
AVR
VAR Calculated Calculated
Manual SP
from from VAR SP of
of Active SP = 0%
Standby AVR Standby AVR Active AVR
AVR
Openloop Calculated Calculated Calculated
Manual SP
from from from
of Active SP = 0%
Standby AVR Standby AVR Standby AVR
AVR
Measurements Measurements Measurements

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The dark-gray cells show the setpoint follow-up taken from the CAN Interface (more
reliable)
In order that the channel take over the previous operation point as fast as possible, the
PWM of the standby channel starts regulating with the same PWM value of the main
channel.
DCH Communication: Configuration and Compatibility

As explained in Chapter 3.4.4.4.3 DCH Monitor Functions
DCH communication must be enabled to use the Changeover feature. When the DCH
communication is enabled, measurement, setpoints and status indications from the
Second Channel are read and valid as long as the DCH Communication Status is logic
one; i.e. correctly configured, enabled and free of communication errors.
The Double Channel software is only partially compatible with the UN1000-PM40
module. The DCH Supervision can be used together with UN1000-PM40, because it
does not depend on the CAN communication status and activation. However, a PM40
module cannot be used in the same device, where Changeover and/or DCH Follow-up
features are also required. Even whenever DCH Communication can be enabled, the
operation of the UN1000-PM40 has a higher priority and the DCH data transmission will
be stopped as soon as the AVR detects a UN1000-PM40 on the CAN bus. This priority
order is fixed in the AVR and not configurable.
Even without functions from Redundant Channel support, a double channel system with
UN1000-PM40 can be built using analog and digital inputs and outputs as communication
interface between the AVRs. Furthermore, Alarm and Trip output signals from DCH
Supervision could be used to extend the functionality to some extent.
The AVR-ID should be configured with the same number in both channels. One channel
should be configured as Main and the other as Redundant. The channel identification can
be configured using the CMT1000 or Remote Access. Only one channel should be Active
while the other is in Standby. The use of interlocked contacts (connected externally) is a
recommended practice to assure this situation. The Standby/Active status of both
channels can be monitored using the CMT1000. For more information refer to Chapter
6.4 PC Software Tool.
3.4.4.5 Rotating Diode Monitoring (RDM)
The aim of the Diode Monitoring is to detect 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 in Figure 3-16.

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Regulator
ie AC Exciter Synchronous Machine
Ie
Figure 3-16 Rotating Diode Monitoring application
RDM parameters
Nominal exciter frequency f Exc Nominal [Hz]

(Machine) :
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.
The machine frequency must be configured prior to using RDM (in the System Data) in
addition to the above-mentioned RDM parameters.
Detecting an alarm or trip is based on the level of ripple current on the exciter frequency,
where the filter is tracked by the measured machine frequency. So in order that RDM is
working correctly the machine voltage must stay above 10% nominal voltage.
3.4.4.6 Data Logger
The Data Logger is a SW-Option. If this SW-Option is not enabled there is only a reduced
functionality available.
It can record max. 12 signals, 7 of which are fixed and 5 of which can be programmed
individually.
Fix predefined signals

 Generator Voltage
 Generator Current
 Reactive Power
 Excitation Current
 PWM
 Generator Status
 Generator Operation Mode

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The number of samples is limited to 2000 samples/signal. If the SW-Option is disabled
the recording will be limited to 200 samples/signal.
3.4.4.7 Event Monitor
Events are stored on non-volatile flash and can be read out by MODBUS requests. Event
triggering signals are grouped as follows:
 Generator state changes
 Active Mode changes
 Limiters ON and OFF
 Alarms
 Trips
 Excitation ON (operation mode)
 Parameter change
3.4.5 Miscellaneous Functions
3.4.5.1 History Logger
The History Logger records the last two hours of operation. A measurement sample of 12 defined
signals is stored in the non-volatile flash every minute. Each time the excitation is started the
default values are stored in the log to identify restart conditions.
Table 3-4 Recorded signal of History logger
Signal Signal identification Value of start Exc.
Machine voltage Umrel 0%
Machine current IM2rel 0%
Reactive power Qrel 0%
AVR output PWM PWM 50%
Generator state GenState 0
AVR Control mode Generator control mode 0
Machine frequency fMachine 0Hz
Limiter status Combined Limit 0
Active Power Prel 0%
AVR input voltage (rectified) Upwr 0V
Temperature of controller Temperature DSP 0°C
3.4.5.2 FCB Control
Field circuit breaker control

FCB Control is an alternative way to control the field circuit breaker. The control is active,
when the FCB command signals are configured.

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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
In redundant channel operation the FCB closing works as follows:

 Main channel: FCB close command is given when Ex. ON command is received
as described above
 Redundant channel: FCB close command is given as soon as the redundant
channel becomes active (Standby not active)
Open FCB command is given only in case of received Exc OFF command regardless
whether the AVR is active or in standby operation.
3.4.5.3 Miscellaneous expert functions
Details on expert functions are described in a separate document.
Functions Description Required SW Option

Adjust PID output by multiplying the frequency
gain correction.
Kc Freq Dep (2) PWM Inversion
a) Kc Freq Dep Linear
b) Kc Freq Dep 2 Both selected: square
Safety feature for marine applications.
Hold ExcOn when GCB
Excitation OFF can only be achieved after GCB None
closed
was closed in case GCB status is open again.
Um Filter ena BS 50Hz to
Add filter on calculated RMS value None
200Hz
Um Filter ena LP 25Hz Add filter on calculated RMS value None
PID integrator anti windup logic disabled in case
UnSym. Anti Windup None
of negative error until integrator is set to 0.
Compounding AVR Inverts the PWM output signal PWM Inversion
Monitor function “Loss of Excitation” is disabled
in standby mode. When changing from standby
Switch OFF Loss of Exc. to active mode, a delay of 5 sec of switching on
Delay monitor function is implemented. Options will
activate monitor function at once when AVR
becomes active
Field Voltage Limiter See separate chapter None

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Kp Setting of derivator gain None
Adjustment of kceiling depending on input
Upwer@Nolad None
voltage
High initial Response controller:
Fast proportional exciter current regulator,
HIR Controller processing the output AUTO PID regulator as an None
input to fast exciter current regulator.
Improves stability for very high ceiling factors
Limits PWM output
Ve Limiter None
Improves stability for very high ceiling factors
Non-linear error of AUTO Non-linear error amplification depending on
None
PID configurable threshold
Manipulating voltage measurement signal by
multiplication of time profile
FRT Testing None
Attention: The machine will boost and deliver
extensive Q to the network
3.4.5.4 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 oscillations in synchronous generators through
additional influencing of the excitation. The main application is in excitation systems in
single or multi-machine power plants.
Electromechanical oscillations can be classified into 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/2C type model functionally represents the PSS.
This model is shown in the figure below.
The object of the power system stabilizing (PSS) equipment is to increase the generator
exciter‘s contribution in order to improve the stability of 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.

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Frequency injection Lead lag injection

Scaling: ±0.1% to ±1.0% Scaling: ±0.1% to ±1.0%
TP
TP Delta P RAMP-TRACKING
WASH-OUTS Integrator Filter PSS-Gain LEAD-LAGS
USTmax VSTmax
TP TP TP TP TP TP TP
+ +
sT1  1 sT3  1 sT10  1 sT12  1
N
Synthesized + + sTW 1 sTW 2 + +  sT8  1  ++ +
PID
rotor speed ω    M   K S1 UST_PWM
[delta pu] sTW 1  1 sTW 2  1  ( sT9  1)  sT2  1 sT4  1 sT11  1 sT13  1 (AUTO)
+ -
TP TP
Ks3 USTmin VSTmin
TP TP TP
+ sTW 3
Power +
+ + sTW 4 KS 2

P [delta pu] sTW 3  1 sTW 4  1 sT7  1
PSS TP output 1: Free configurable (blue dots)
PSS TP ouptut 2: Free configurable (blue dots)
TP
Remark:
Settings of PID are interlinked to AUTO-PID (Voltage regulator)
UST_PWM is added to the AVR output
Power injection
Scaling: ±1.0% to ±10.0%
Figure 3-17 PSS model.
Figure 3-18 shows a simplified diagram of the PSS and related functions
UM V1 PSS
Frequency
IM2 Calc
f
PSS
V2
Power
Calc
Pe
Figure 3-18. Simplified diagram of PSS.
The frequency input is based on synthesized frequency measurement taking into account
terminal voltage as well as machine current.
Due to the PSS function implementation and structure of UNITROL 1020 AVR, there are
some points to be noticed when using this PSS. The following elements limit the
maximum performance of the PSS:
 Brushless excitation system,

 Positive field voltage (only) can be supplied.
PSS Parameters
The PSS function can be activated by the PSS_SELECT configuration and by digital input
or over Modbus.
If digital input “PSS Enable” is activated, PSS activation only depends on the status of the
digital input. Otherwise PSS activation is defined by the parameter PSS-Select or the
Modbus control bit.
PSS is blocked in case the machine voltage is below 0.8 p.u., above 1.2 p.u. or active
power is below the defined threshold. In addition, the PSS can be blocked by configurable
frequency gradients.
The PSS feature is only functional if the PSS SW Option is released on the unit.
The PSS signal comes either from the internal PSS or from the analog input ‘External
PSS’. The switch is controlled by a checkbox in the PSS setup.
When the switch is set to external PSS, the internal PSS calculation can be skipped.

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The parameters are not explained here. For more information refer to the following
documents:
 UNITROL 1020 Power System Stabilizer (PSS) Engineering Notes
Doc. No. 3BHS351450 E01
 Simplified Computer Representation for Power System Stability Studies
UNITROL 1020 and UNITROL 1010
Doc. No. 3BHS354059 E01

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3.4.6 Modbus for Remote Access
Remote Access is a feature that allows monitoring and control of the AVR using the
MODBUS protocol. It can be suitable for applications where the control from remote
locations is preferred (i.e. offshore) and/or a custom user interface is required.
The following sections explain the Remote Access software and configuration. The
electrical connections are described in Chapter 3.3.9 Communication Ports. It is
recommended to read Chapter 3.4.7 Access Levels prior to this section, in order to fully
understand the software capabilities.
3.4.6.1 Overview
A remote terminal configured as MODBUS master can access the device through RS485
or Ethernet TCP/IP using Remote Access. The communication choice is up to the
application requirements but since VDC needs a dedicated RS485 connection, Ethernet
TCP/IP is the only choice when VDC is used. When VDC is not needed, Remote Access
can be performed using the RS485 interface. More information about the communication
interfaces can be found in 3.3.9 Communication Ports.
The Remote Access feature allows the user to read and write registers (measurements,
setpoints and other information) from the AVR. The document that describes the
MODBUS Registers Table is normally included in the CD-ROM that comes with new
devices. It can also be ordered from ABB. The manufacturer details and contact
information can be found in Chapter 1.5 - Manufacturer’s Address.
The feature supports up to one MODBUS remote terminal and it must be assured that
requests are sent from only one remote terminal using the same communication interface
(RS485 or Ethernet TCP/IP). If more than one request comes from different interfaces,
they might be answered via the same interface from where they come. This method is
however not recommended and should not be used.
In order to communicate with the device, the remote terminal should gain a determined
access level in the AVR according to the operation desired: Monitor Access for reading
only and Control Access for reading and writing to registers. More information about
Access Levels can be found in Chapter 3.4.7 - Access Levels.
3.4.6.2 Compatibility
The Remote Access feature over RS485 cannot be used together with VDC. If both
Remote Access and VDC are required, Remote Access should be used via TCP/IP using
an external gateway. When VDC mode is not required, Remote Access can be used via
either RS485 or Ethernet. For more information see Chapter 3.3.9 - Communication
Ports.
3.4.6.3 Configuration
Remote Access over RS485 has a number of parameters that should be configured:
Protocol (Modbus RTU or TCP), Activation (of the feature over RS485), Baud Rate,
Answer delay and others shown in Chapter 6.4.7 Communication Menu.
The Modbus Slave ID value is used for both Remote Access over RS485 and Ethernet
TCP/IP; there is no differentiation of the physical interface. This number can be

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configured between 1 and 247; the latter being the default value. A restriction applies
when the number is configured between 1 and 63 (except 32) and matches with the AVR
ID number for main channels or AVR ID number +32 for the redundant channel.
In these situations, the AVR will change the Remote Access Slave ID to 247 upon restart.
The Modbus Slave-ID for Remote Access can be configured between 64 and 247 without
restrictions. This is the range which is recommended for most applications.
The Modbus slave ID used for CMT1000 access is a number between 1 and 63, which
depends on the AVR-ID and the Channel Identification (Main or Redundant), even if the
Double Channel feature is not being used. When the parameterization is done using the
CMT1000, the Modbus ID used for CMT1000 is shown in the MODBUS Supervision
window. This number should not be used as Modbus Slave ID for Remote Access. For
further information refer to Chapter 6.4.7 Communication Menu.
3.4.7 Access Levels
Generally, digital inputs have the highest priority when controlling the AVR. Remote
access for control signals, e.g. Excitation ON, is only possible if the digital input is not
assigned.
The UN1020 device can be accessed from three different operators: Front Panel,
CMT1000 or Remote Access. While all operators can read data simultaneously, only one
of them can have control access and is allowed to write or change parameters in the
AVR. This concurrence is managed in the AVR main controller by assigning, to each
operator, a determined Access Level or privilege:
 Local control mode (default)
The UN1020 device is by default in local control.
 Front panel control (highest priority)
The customer can take over control to change parameters, the UN1020 device will
automatically switch back to local control mode
Customers who are taking control by the panel will block out other operators
 CMT1000 control (medium priority)
CMT1000 can be connected to the target, where three different access levels are
defined: Offline, Monitor and Control.
If front panel control is granted, then CMT1000 cannot be set to control mode in
order to change parameters.
CMT1000 will block out other CMT1000 applications or remote access of plant
control system if CMT1000 control mode is used.
In case CMT1000 is disconnected from the target the UN1020 device will go back
to local control mode.
 Remote access (lowest priority)
Remote access is granted only if the UN1020 device is in local control mode.
The Access Level status of each operator is stored in the AVR main controller and is
used to grant and deny access requests. An operator can request the change of its
Access level to the AVR main controller, i.e. from Monitor to Control. Access changes to
Monitor are normally granted without restrictions since all sources can read
simultaneously from the AVR.
An Access Level changing request can be denied when more than one CMT1000 and/or
more than one Remote Access device are trying to establish a connection to the same
AVR. The UN1020 supports a simultaneous connection of one CMT1000 and up to ten

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independent Remote Access connections per device (maximum). If those limitations are
surpassed, one or all connected operators can lose their access and go Offline. This
practice is not recommended by ABB. The method to change Access Levels from Panel,
CMT1000 and Remote Access is explained in the following sections. For more details
about UN1020 user interfaces, refer to Chapter 6 - Operation.
3.4.7.1 Panel
The Panel is normally in Monitor mode. By clicking the LOC button, the access right is
given to the panel. All other operators are blocked out.
3.4.7.2 CMT1000
The CMT1000 manages the Access changing requests (Offline, Monitor and Control) by
using a graphic slide-bar displayed in the software main window. The slide-bar shows the
CMT1000 current access status from the AVR and allows the user to simply change it by
sliding up and down. For more information about the user interfaces see Chapter 6 -
Operation.
Changing to Control mode is not granted if the panel is in local mode. If the Plant control
system is in Control mode over remote access, the CMT1000 forces it into Monitor mode.
This means the plant control system has only read access.
 Offline or disconnected (no access)
If the status of an operator is Offline, the AVR microcontroller considers the
operator as not connected to the UN1020 and, therefore, there is mainly no data
exchange with the AVR. Only when using the CMT1000 as operator and the
presence of a compatible AVR is detected, a small quantity of data is exchanged to
provide and display the AVR-ID information on the main window of the software.
 Monitor (read access)
If an operator has Monitor Access, it is only possible to read data from the device
(i.e. measurements, parameters, etc.). Data cannot be changed or modified in the
AVR during this access mode. All the operators, i.e. Panel, CMT1000 and Remote
Access, can have Monitor access to the AVR at the same time; all of them can read
simultaneously from the same AVR.
 Control (read and write, full access)
If an operator has Control Access, he has full control of the device (write and read
data). All operators can request Control Access, but the access will be granted to
only one operator at the same time, based on the operator's priority.
3.4.7.3 Remote Access
Changing of Access Levels from Remote Access is performed by requests via Modbus
protocol. Control access level is only granted if no other operator is in control mode. For
more information, refer to the UN1020 Modbus Reference document: Doc. No
3BHS358281 E80.

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
Chapter 4 - Installation and Storage
4.1 General
Chapter 4 – Installation and Storage provides all instructions for

installation and storage of the excitation system. It also contains
information on how to dispose of and recycle materials.
NOTICE!
First read and understand the general safety instructions in Chapter
2 - Safety Instructions before starting to work with the excitation
system.
NOTICE!
Converter components can be damaged while transporting the
excitation system.
4.3 Unpacking
The unit should be unpacked with the maximum 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 visibly damaged:
 Safe operation is not possible.
 The unit must not be installed and taken into operation.

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Chapter 4 - Installation and Storage 

4.4 Mechanical Installation
The unit is mounted by means of four

screws.
See dimensional diagram for fixing holes
and spacing.
Mounting instructions see Chapter 3.3 -
Hardware
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.
Mounting
Rack mounting Wall mounting

The UNITROL 1020 is designed for
rack or wall mounting in upright
position.
50 mm
A distance of approx. 50 mm around
the unit shall be kept free for optimal
cooling.
50 mm
111 mm
NOTICE!
Electrostatic discharge (ESD) can damage electronic boards and
components!
 Do not touch printed circuit boards or other sensitive
components without taking static-sensitive handling
precautions.
 Do not touch the components without wearing a wrist
grounding strap.
 Put the board or component on a grounded working surface
which is protected against electrostatic discharges.
 Hold a board only at the edge.
 Handle a faulty board with care.

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 Chapter 4 - Installation and Storage
4.5 Electrical Installation
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 grounded 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 17 0.2 to 4 mm2 (AWG 24 to 10)
- Electronic sections, terminal numbers 20 to 77 0.2 to 2.5 mm2 (AWG 24 to 12)
The casing must be grounded at terminal 17 with 4 mm2. Additional earth

terminals are provided for the shielded cables. The ground connection
should be kept as short as possible.
NOTICE!
Excitation cables longer than 3 m should be shielded. If not, there is
a risk of severe EMI-distortion.
4.5.1 Digital and analog IO cabling 1020
Digital and analog IOs are referenced to PE, meaning analog and digital
ground (Dx / BOx) is connected directly to PE.
Therefore the maximum cable length is limited to 30m.
In addition the following recommendations shall be followed:
 <3m: none
 3-10m: Twisted pair cable
 10-30m: Shielded cable with one PE connection close to the
UNITROL 1000 device.
 >30m: not allowed
Digital and analog IO cables must be separated from any power or
measurement cable
4.5.2 Inrush current of UNITROL 1020
Due to the large internal DC capacitor the inrush current might become
very high especially with a strong voltage source.

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Following instructions must be followed in order not to damage UNITROL
1020
Excitation power is taken from the generator output over

a shunt transformer
Shunt supply
 Always use excitation supply transformer
 Excitation transformer must not exceed 10 kVA
Excitation power is taken form PMG

PMG supply
 PMG output power must not exceed 10 kVA
Excitation power is taken from additional stator winding

Auxiliary of the generator
Windings
 No measures must be taken
Excitation power is taken directly from an auxiliary power

source
Auxiliary supply
 Use always excitation supply transformer
 Excitation transformer must not exceed 10 kVA
Excitation is taken from a battery

DC battery
 Inrush current must be limited by a resistor
Inrush can be easily calculated assuming that the capacitor voltage is 0V

at startup. The external resistor for 200Vac input is typically 1.5Ω.
NOTICE!
This inrush current must be limited to 200 A average for 10 ms,
otherwise the unit might be damaged
4.5.3 Extended operation lifetime with external capacitor
Operation lifetime is limited by the internal capacitor used to filter the

excitation input power. The operation lifetime is influenced by:
a) Ambient temperature, +10 °C decreases lifetime by factor 2
b) Nominal excitation output current
c) Source of input voltage, DC, 3-phase or single-phase
The following table defines when an external capacitor is needed in order

to have a suitable operation lifetime.

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 Chapter 4 - Installation and Storage
Table 4-1 Operational Lifetime Chart for UNITROL 1020

Operational Lifetime Chart for UNITROL 1020
Light Grey: No external capacitor needed

Dark Grey: External capacitor needed
Black: No operation possible
Excitation Current 5A to 8A to 10A to 15A to Ambient

<5A
Supply 8A 10A 15A 20A Temperature
<30°C
30° to 40°C
1 phase input
40° to 55°C
55° to 70°C
<30°C
3 phase or DC 30° to 40°C
input 40° to 55°C
55° to 70°C
4.6 Storage
The storage procedures described below must be followed in order to

avoid damage or a degradation of quality due to corrosion, dirt or
mechanical damage. The corresponding precautions must be observed
from the time the equipment is put into storage until the time it is taken
out of storage and installed.
4.6.1 Storage Conditions
The equipment must be stored in the original packing.

Make sure that the following environmental conditions are fulfilled during
the entire period of storage. ABB recommends keeping the air
temperature and the relative air humidity constant:
Air temperature: 0 °C to +55 °C
4.6.2 Disposal
Used materials can serve as raw materials for recycling or other

purposes. For an ecological separation of materials and waste handling
contact your community or the local waste disposal company.
The printed circuit boards are simple to remove. The boards must be
removed and should be disposed of by a licensed disposal company.
Environmentally hazardous elements such as capacitors must be
separated from the boards.
Dispose of the following components according to local regulations:

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1. Capacitors
2. Printed circuit boards
3. Electronic components
4. Batteries
4.7 Recycling Instructions
The inappropriate disposal of electrical equipment can lead to an

environmental hazard. It is therefore important that electrical equipment
be disposed of by qualified personnel.
The metallic casing, cover and front frame do not present any
environmental risk and can be recycled.
The circuit boards must be removed and should be disposed of by a
licensed disposal company. Environmentally harmful elements such as
capacitors must be separated from the circuit boards.
The Unitrol 1000 devices are environmentally friendly designed. The
circuit boards are easy to remove.
Product disposal can be made in two alternative ways. The product can
be disassembled manually or crushed in a shredding machine.
4.7.1 Manual Disassembly
The product is disassembled manually and parts are sorted according to

their material contents as follows:
• Aluminum (cabinets, heat sinks etc.)
• Plastics
• Printed circuit boards
Metal parts (iron, copper and aluminum) can easily be recycled, other
materials according to local arrangements.
4.7.2 Mechanical Shredding
In this method, a whole product is mechanically shredded into small

pieces. Materials are sorted using dedicated sorting processes.
Components containing harmful materials must however be removed
before shredding.

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
Chapter 5 - Commissioning
5.1 General
The commissioning should be carried out by certified commissioning

personnel.
The safety regulations according to Chapter 2 - Safety Instructions must

be followed.
WARNING!
! UNITROL 1020 units operate with dangerous voltages of up to 300 V ac

or 300 V dc.
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 1020 unit are to be touched and/or attached only with 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.

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Chapter 5 - Commissioning 

5.3 Setting Aids
All parameters have to be controlled at the first commissioning.

See the description of the parameters in Chapter 3.4.1.6 Description of
Parameters and settings recorded in Chapter 7.3 - Standard Procedures
for Maintenance.
Parameter Settings, Default Values
Overview of parameter blocks

Setup System Data
Soft Start
Field Flashing
Limiters
Setpoints
Voltage Droop Compensation
Digital I/Os
Analog Inputs
Analog Outputs
Synchronization
Diode Monitoring
PSS
Double Channel
AVR Time and Date
Data Logger
Communication ID Definition
Port Configuration
AVR Ethernet Settings
MODBUS Supervision
VDC Monitor
Tune Setpoint Adjust
Auto
PF/Var/PQ Limiter
Manual/Ie Limiter
5.3.1 Setting Aids
5.3.1.1 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
Regulator
Ueo: Output voltage at nominal
voltage of the machine U emax
(machine in no-load SM E U eo
operation)

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 Chapter 5 - Commissioning
PWM no load: Regulator output at no load (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 = 1.35 * 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.
NOTICE!
The Kceiling value must be in the range of 5 to 15 in order to
achieve optimal and stable regulation. If not, the input voltage
value may have to be reduced.
NOTICE!
The ceiling value must be calculated for a machine working at
nominal load, therefore ceiling factor measurement with PWM can
only be considered after the machine reaches nominal operational
temperature.
5.3.1.2 Setup \ System Data, Machine Reactance Xq (non-saturated)
- Salient pole machine: Xq ≈ 0.7 to 0.5 Xd

- Cylindrical-rotor machine (Turbo): Xq ≈ Xd

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5.3.1.3 Setup \ Soft Start
Soft start must match the start-up time of the machine. Soft start ramp should reach
100% nominal voltage after the machine reaches nominal frequency.
5.3.1.4 Setup \ Field Flashing
Field flashing must start to build up voltage, but on the other hand must not over-excite
the machine. Designing a proper field flashing is a demanding engineering task.
Maximum excitation current of field flashing circuits must be between 10% and 15% of
Ie no load.
5.3.1.5 Setup \ Limiters, in Manual and Open Loop Mode
No limiters are active in Manual and Open loop mode.
5.3.1.6 Setup \ Limiters \ Operational Limits \ 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%
5.3.1.7 Setup \ Limiters \ Operational Limits \ Ie Limiter
Depending on the machine data and recommendations of the machine supplier.
5.3.1.8 Setup \ Limiters \ Operational Limits \ IM Limiter
5.3.1.9 Setup \ Limiters \ Operational Limits \ Q Limiter
5.3.1.10 Setup \ Digital I/Os, Configuration
Software configuration of the digital I/Os

 Define terminal as input or output
 Assign terminal to desired signal
 Select polarity

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Note:
Digital IO can be configured at the same time as input and output
5.3.1.11 Setup \ Analog Inputs / Outputs, Configuration
Software configuration of the analog inputs

 Assign terminal to desired signal.
 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.
Software configuration of the analog outputs

 Assign terminal to desired signal.
 Define signal level of the output signal [Uout 0% to Uout 100%].
 Define signal level of the field current [Ie 0% to Ie 100%].
5.3.1.12 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 to be assigned
Stand SYN Gen CB Parallel Manual Open Loop VDC PF Var

by Closed with Grid Enable Enable Enable Enable Enable
Status 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 DI13 to DI18 can be used as virtual digital inputs even if they are not defined in
Analog Inputs as Digital Inputs.
5.3.1.13 Setup \ Synchronization
The machine frequency must always be higher than the network frequency and cannot be
synchronized by a positive slip.

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5.3.1.14 Setup \ Diode Monitoring
The Nominal Exciter Frequency has to be adjusted. For the others, the default value has to
be kept.
fexc = Pexc x fgen / Pgen fexc Nominal Exciter frequency

Pexc Number of pole pairs in exciter machine
fgen Nominal Generator frequency
Pgen Number of pole pairs in generator
5.3.1.15 Setup \ PSS
ABB offers PSS parameter calculation and stability studies, contact us for further
questions.
For more information refer to following documents:
 UNITROL 1020 Power System Stabilizer (PSS) Engineering Notes
Doc. No. 3BHS351450 E01
 Simplified Computer Representation for Power System Stability Studies
UNITROL 1020 and UNITROL 1010
Doc. No. 3BHS354059 E01
See manufacturer’s details, Chapter 1.5 - Manufacturer’s Address.
5.3.1.16 Setup \ Double Channel
The configuration of Double Channel depends on the application and connections. For
detailed information about configuration, refer to 3.4.4.4 Double Channel (DCH).
5.3.1.17 Tune \ Setpoint Adjust, Step
Mode Maximum adjustable setpoint jump during 10 s

Manual ±50%
Open Loop ±20%
PF ±0.2
Var ±50%
Auto ±20%
5.3.1.18 Tune, Order of Priorities
If several operating modes are selected simultaneously by the digital inputs, the following
order of priority applies:
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

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Priority Mode Remark

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
5.3.1.19 Tune, Auto
The PID tuning tool is on the CMT1000 CD. The following settings can be preset on the
basis of the machine data.
Integral time constant Ta

This lies within the range of Td‘ of the main machine.
Setting: Ta = 1.0 to 1.5 x Td‘ (Typical value 2 to 5 s).
(Optimized for load conditions)
Derivative time constant Tb

This approximately compensates the load time constant TE of the exciter machine.
Setting: Tb = 0.7 to 1.0 * TE (Typical 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.
Note: Since the Kceiling affects Vp from all the operating modes, be sure to calculate this
value before tuning the AVR. If Kceiling has changed after tuning, the AVR shall be re-tuned
again.
Reactive power influence Kq

In case of machines which, without step-up transformers, are connected to the fixed grid
or, via a busbar, to 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. This stabilizes the reactive power output or
consumption in those configurations. 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 = +7%
= 12% - 5%
 After step up transformer

Drop of 5%

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5.3.1.20 Communication \ MODBUS (Remote Access)
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 to true, then the parameters
have to be written to the EEPROM. Afterwards, the UNITROL 1020 must be restarted.
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 by MODBUS
itself and therefore losing connection to the UNITROL 1020.
Standard Configuration Answer Delay: 10 ms

Bit Rate = 19200
Character Framing = even
RTU: Protocol of the RS485
Slave ID
Zero and values higher than 247 are reserved, so the valid range for the slave ID is 1 to
247. The default value is 247. Recommended range is 64 to 247 due to the possible
influence with the Modbus ID used for CMT1000 access. For more information refer to
Chapter 3.4.6 – Modbus for Remote Access
Keep-alive time
The parameter “MB_KeepAliveTime” defines in what time-period 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 events can be selected with the “MB_KeepAliveAction”.
Priority of input signals

All signal assigned to a physical input (digital or analog) cannot be overwritten by modbus
remote acces, and data are ignored
Configurable modbus signals

UNITROL 1020 provides a free configurable signal list to read out required signal with one
access.
Access Levels
Modbus Remote Access shares the control of the AVR with the CMT1000 and the SCP
Panel. The control access has to be granted as explained in Chapter 3.4.7.
For more information, refer to the UN1020 Modbus Reference document, document
number 3BHS348611 E80

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5.4 Work carried out while Machine is at Standstill
Preliminary Checks
 Wiring check, compare connections with schematics.
CAUTION!
Check the insulation strength of the plant with the insulation tester
During the test, the equipment could be damaged by the testing voltage.
Disconnect cables to the UNITROL 1020
 Switch on auxiliary voltage UAUX

 Adjust parameters
 Check measuring voltage and current transformer circuits
 Measure field resistance
 Checking input and output signals
 Low-load test: External power electronics supply (3x <300 V ac)
- Open loop mode
- Optimize regulator Ie
 Adjust limiter settings based on the customer’s power chart
5.5 Work carried out while Machine is running
5.5.1 No-load Tests (nominal speed, not synchronized)
 Field flashing and discharge in Auto and Manual mode

 Soft start in Auto mode
 Adapt setpoint range, optimize voltage regulator
 V/Hz limiter: The actuation point fknee is set to 48 Hz by default
For 60 Hz machines the fknee should be set at approximately 58 Hz.
5.5.2 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

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 Optimize Iemin / Iemax Limiter
 Optimize PQ Limiter
The setting of the PQ limiter must be coordinated 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.
5.5.3 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,
caused by wrong connection or ratio of PTs on
the grid side and generator side.
Another prerequisite is the correct rotating

direction of the three phases on the machine
and line side.
 Measurement of the phase angle of the voltages UNET and UM

Open the isolator, close the circuit breaker (CB). Due to safety reasons the
measurements have to be obtained not only from the Monitor\Oscilloscope or
Monitor\Sync Diagram but also from an external oscilloscope.
 “Blind” synchronization
Monitor the Synchronoscope (Monitor\Sync Diagram) by disabling the closing
mechanism of the circuit breaker.
 “Live” synchronization
Record the event with a Synchronoscope.
CAUTION!
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.

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CAUTION!
In this status, the phase-angle difference must be 0 deg. Otherwise the
measuring cable is incorrectly connected. Incorrect polarity cannot be
detected by the UNITROL 1020. Paralleling with incorrect polarity can
lead to serious damage.
A phase shift caused by one of both measuring transformers or by the
connection group of a step-up transformer must never take place.
CAUTION!
Be careful when the opening the star point of the primary voltage range
of the PT
5.6 Concluding Work after Commissioning
Write the currently adjusted parameters to EEPROM so that they are saved in
the device. Save the corresponding settings into an INI file or print the INI file
(see Chapter 9.3 – Parameter Settings, Default Values).
The INI file can be opened using an editor (Word, Note- or WordPad) and
printed.

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
Chapter 6 - Operation
6.1 General
NOTICE!
ABB recommends periodical training for operating personnel
DANGER!
Dangerous voltage.
There is a danger of electric shock.
NOTICE!
Before operating the excitation system the general safety instructions in
Chapter 2 - Safety Instructions must be read and understood.
CAUTION!
Parameters are set during commissioning of the device and must not be
changed afterwards without taking into consideration the consequences
they can produce.
Running the excitation system with incorrect data can result in improper
operation, reduction in control accuracy and damage to the equipment.
Only qualified and certified personnel are allowed to operate the device,
i.e. personnel who are familiar with the excitation system and the
hazards involved.

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Chapter 6 - Operation 

6.3 Panel Operation
The panel is operated using the buttons from the keypad installed in the front. The Panel
can even be used to read measurements and/or change parameters in local operation.
6.3.1 Panel Start-up
After powering up the device (UAUX power) the panel performs an initialization stage to
establish the communication with the AVR main controller.
1. During power up the panel tries to UN IT RO L

establish communication with the AVR 10 2 0
main controller. During this process the
panel displays the information shown in Figure 6-1 Panel screen just after
connecting Uaux power.
Figure 6-1
2. Few seconds after the SW revisions REM 100.0% S

have been shown, the panel shows the AUTO NoLoad
main menu as in Figure 6-2. The panel 0.00 % UM
can now be operated using the Keypad. 0.00 A Ie
SETPNT 12:45 MENU
Figure 6-2 Main menu. The panel can
now be operated.
6.3.1.1 Connection Problems
When the panel is unable to communicate

with the AVR main controller due to AVR Not Responding
hardware problems, the screen might show
the message displayed in Figure 6-3. This Figure 6-3 Message shown when
message can also appear when the panel communication problems occur
and AVR main controller (DSP) firmware between panel and AVR controller.
are incompatible each other; which might
occur after a firmware upgrade.
However, regulation and protection
functions are normally still in operation,
without being influenced by communication
problems with the panel.

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 Chapter 6 - Operation
6.3.2 Display elements
Alarm and Limiter Indication Setpoint:

Operator Access: E: Excitation ON
LOC: local Highlighted: can be changed
L: Limiter
REM: remote A: Alarm Saved:
Appears when parameters
Active State: L are saved
Standby Generator State:
Sync Grid
Manual Sec. Net
Open Loop Prim. Net
Pf NoLoad
Var
VDC
Auto
Function of Softkey Buttons
6.3.3 Keypad Operation
Key Command
Up, Select mode: Moves the highlighted line up or down

Down
Settings: Decrements or increments the highlighted value of a
selected parameter and the value of the setpoint
Soft key Select SETPNT: Highlights the setpoint value for changing the value
Left Select EXIT: Returns to the last state
Continue to click EXIT until the main display appears.
Soft key Select MENU: Selects main menu

Right Select ENTER: Selects submenu of the highlighted line
Select SEL: Selects the highlighted Parameter or Clock Set group
Select EDIT: Edits parameters (mostly write-protected)
Select ENTER: Confirms the form of date or the new value
Select CANCEL: Returns to the last menu without change
Select OK: Confirms the time and date of the new value
Select EXIT: Returns to the last state
REM/LOC Select remote or local operation, click twice for local operation in case
CMT or fieldbus remote access is active.
The panel switches back to remote mode after 1 min without user
interaction.
Remote: Panel has no write access rights, only indications
Local: Panel has full write access and blocks CMT and field
bus remote access

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? Not used
STOP Not used
START Not used
6.3.4 Emergency Excitation OFF
Activate or deactivate Emergeny Excitation OFF

Panel must be in local mode to enable the START/STOP buttons.
Signal from panel is overwritten by emergency excitation signal from digital IO, when configured.
 STOP sets the Emergency Excitation signal to 1 (= excitation disabled)

 START sets the Emergency Excitation signal to 0. (= excitation enabled)
6.3.5 Setpoint Adjustment
The panel uses INCREASE and DECREASE commands to change setpoint within DSP.
Thus setpoint changes according to ramp rate settings of DSP settings.
Setpoint mode must be left by user, it is not left automatically after a certain time with no user
interaction.

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6.3.6 Menu Structure
Main screenshots Menu items
REM 100.0% E
AUTO NoLoad
0.0 V UN
0.0 kV UM
SETPNT 12:45 MENU MENU
REM I_MAIN MENU 1

PARAM/SIG
CLOCK SET
EXIT 12:46 ENTER ENTER
REM I_GROUPS 01
01 Commands
02 Measurements
03 2nd ch Measurement
04 Supervision Status
05 Limiter Status
SEL
EXIT 12:47 SEL
PARAM/SIG
01 Commands 0101 RESET ALARM
0102 Save to EEPROM
0103 AUTO Step
0104 PF Step
0105 VAR Step
0106 MANUAL Step
0107 OpenLoop Step
02 Measurements 0201 Mode

0202 Machine Voltage
0203 Machine Vol rel
0204 Exc. Current
0205 Exc Current rel
0206 Net Voltag rel
0207 Machine Current
0208 Machine Cur rel
0209 Reactive Power
0210 React Power rel
0211 Active Power
0212 Act Power rel
0213 Net Frequency
0214 Machine Freq
0215 Power Factor
0216 DI Emergency OFF
03 2nd ch Measurement 0301 AVR2_Mode

0302 AVR2_ActiveSP

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0303 AVR2_ManualSP
0304 AVR2_Umrel
0305 AVR2_UnetRel
0306 AVR2_IM2rel
0307 AVR2_Iqrel
0308 AVR2_IeAbs
0309 AVR2_CntrlSWVer
04 Supervision Status 0401 Watchdog

0402 Loss of RC
0403 Part Loss UM
0404 Loss UM
0405 Loss CT
0406 UML1 Freeze
0407 UML2 Freeze
0408 UML3 Freeze
0409 Unet Freeze
0410 IM2 Freeze
0411 Loss of Control
0412 Loss of Exc
0413 Temp Limit 1
0414 Temp Limit 2
0415 External Alarm
0416 RS485 Bad Frames
0417 VDC Ring Error
0418 Int Power Fail
0419 Dig Output Fail
0420 Monitor Alarm 1
0421 Monitor Alarm 2
0422 Supervision Alrm
0423 Supervision Trip
0424 2nd CH Alarm
0425 2nd CH Trip
0426 Switch Over
05 Monitor Fnc Status 0501 FCB Alarm

0502 Diode Alarm
0503 Diode Trip
0504 Gen Over Volt
0505 Gen Under Volt
0506 Exc Over Curr
0507 External Alarm
06 Limiter Status 0601 Active Oper Lim

0602 V/Hz Limiter
0603 SP Min Reached
0604 SP Max Reached
07 Alarms Status 0701 Software Alarm

0702 FCB Alarm

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0703 External Alarm

0704 Modbus Alarm
0705 Diode Alarm
0706 Diode Trip
0707 Supervision Alrm
0708 Supervision Trip
0709 Switch Over
08 Comm Status 0801 RS485 Good Frams

0802 RS485 Bad Frames
0803 RS485 Rcv Frames
0804 RS485 Tx Frames
0805 RS485 Bit Errors
Parameters are listed in the same order as in the CMT1000 menu for Setup, Communication and
Tune. For parameter setup refer to Chapter 9.3

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CLOCK SET
REM 100.0% E
AUTO NoLoad
0.0 V UN
0.0 kV UM
SETPNT 12:45 MENU MENU
REM I_MAIN MENU 1

PARAM/SIG
CLOCK SET ▼
ENTER
EXIT 12:46 ENTER
REM TIME & DATE 02

SET TIME
SET DATE
SEL, Oks
EXIT 12:47 SEL
CLOCK SET
SET TIME Change time and date settings with the panel
SET DATE - Time format is always 24 hours
- Date format is always dd.mm.yy
Can be adjusted in remote and local operation
6.3.7 Setpoint Step
Apply a step to any setpoint. panel is in local mode.

It is the user’s responsibility to choose the right step type according to the actual generator mode. If
the wrong step is chosen, the value will also keep its value for 10 sec, but there is no influence on
the operation of the AVR.
PARAM/SIG 0103 AUTO Step

01 Commands 0104 PF Step
0105 VAR Step
0106 MANUAL Step
0107 OpenLoop Step
6.3.8 Save to EEPROM
PARAM/SIG
01 Commands 0101 RESET ALARM
0102 Save to EEPROM
Setting new parameters over the panel or over CMT changes the parameters in the volatile memory
only. To make the modification permanent, the entire parameter set must be saved.

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6.3.9 Limiters
A limiter triggers the SCP’s limiter response, which causes the panel’s green LED to flash
and a limiter message will be displayed on the screen every few seconds.
Operating Resulting Display
LIMITERS in REMOTE mode REM L 100.0% E

The display periodically switches from the indication view AUTO Grid
to the limiter view and back to the indication view. 0.0 V UN
It is still possible to navigate in the SETPNT or MENU, but 0.0 kV UM
SETPNT 12:45 MENU
the limiter is always displayed for a short time.
The blinking display can be disabled by changing the
REM L LIMITER
panel to local control. Active limiters can be seen in the
parameter/signal group “Limiter status” (Group 05). LIMITER 12
Limiter Active
Example: Limiter 12 = 4 + 8 (see the table below)
The limiters “Max Ie” and “V/Hz” are blinking 12:50
The V/Hz and setpoint limiters are added to the other limiter.
E.g. Limiter 12 display means that Max Ie and the V/Hz limiter are active.
The following limiter numbers can be monitored from the panel:
Limiter No. Description Short Term

0 None
1 Minimum Excitation Current Limiter active Min Ie
2 Minimum Machine Voltage Limiter active Min UM
3 Minimum Iq Limiter active (PQ-Limiter) Min Iq
4 Maximum Excitation Current Limiter active Max Ie
5 Maximum Machine Voltage Limiter active Max UM
6 Reserved
7 Maximum Machine Current Limiter active Max IM
+8 V/Hz Limiter active
+16 Minimum Setpoint reached
+32 Maximum Setpoint reached

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6.3.10 Alarms and Fault Messages
An event triggers the Alarm/Trip state of the SCP. The Alarm/Trip state is indicated with a
red LED. An event message appears on the screen every few seconds.
Operating Resulting Display
ALARM/TRIP in REMOTE mode REM A ALM/TRIP

The fault display periodically switches from the indication ALM/TRIP 1
view to the alarm/trip view and back to normal view. Active Alarm
It is still possible to navigate in the MENU (click the EXIT
12:52 EXIT
button) but the Alarm/Trip state will resume after 10
seconds.
The blinking display can be disabled by changing the
panel to local control. REM A ALM/TRIP
ALM/TRIP 2
Alarms/trip can be cleared in the parameter/signal group Active Trip
commands.
12:53 EXIT
Alarm has higher priority than Limiter, meaning that there
is a moving “A” letter in the running symbol even if there is
an active limiter.
Example: “ALM/TRIP 12” = 0 +4 +8 (see table below)
Syntax meaning: Both External Alarm and Modbus
Communication Alarms active.
The following Alarm/Trip numbers can be monitored from the panel:
Alarm or Trip Nr. Description

0 None
+1 SW Alarm active
+2 FCB Alarm active
+4 External Alarm active
+8 Modbus Communication Alarm active
+16 Diode Alarm active (requires RDM SW)
+32 Diode Trip active (requires RDM SW)
+64 Supervision Alarm active (requires Double Channel SW)
+128 Supervision Trip active (requires Double Channel SW)
+256 DCH SwitchOver active (requires Double Channel SW)
A defective unit should be first reported to ABB in order to send back the unit after
authorization. For contact information, refer to Chapter 1.5 Manufacturer’s Address.

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6.4 PC Software Tool
The PC software tool used with UNITROL 1020 is called CMT1000. Release 6.300 is
compatible with all previous 6.xxx releases but not with releases older than 6.000.
6.4.1 General
Parameter configuration and optimization can be done with the user-friendly software
CMT1000 for Microsoft Windows. CMT1000 accesses the UN1020 device through a serial
connection point-to-point via the USB or the Ethernet port, allowing access from remote
locations. The connection options to use CMT1000 are described in Chapter 3.3.9 –
Communication Ports.
Basic features of CMT1000

 Configuration of parameters
and I/O signals.
 Measurement reading
 Trending function for controller
optimization (Oscilloscope,
Power chart).
 Parameter File upload or
download.
 PID tuning, Setpoint step and
other powerful commissioning
tools.
The CMT1000 software operation is described in Chapter 6.4 – PC Software Tool.
6.4.2 System Requirements for CMT1000 Release 6.300
 Minimum Pentium 1 GHz or equivalent processor. Recommended: Pentium III or

Celeron 1 GHz or equivalent processor or higher.
 Minimum 512 MB RAM.
 Minimum screen resolution of 800x600 pixels. Recommended: 1024x768 pixels or
higher.
 CD-ROM drive.
 Microsoft® Windows TM XP, Vista or Win 7.
 Minimum 10 GB of free hard disk space.

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6.4.3 Installing CMT1000 Software
Distribution rights:
CMT1000 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.“
Put the CMT1000 CD in the CD-ROM drive.

Open the CD root directory
1 Driver Installation
Open CMT1000 Installer
Files\USB Driver.
Double-click
InstallUSBdriver.exe
The following Window appears

and disappears after a few
seconds.
Connect the device with the delivered USB cable to your PC. The window “New Hardware
Found” appears. Click Next until the device is installed.
2 CMT1000 Installation
Open C) CMT1000 Installer
Files and double-click
Setup.exe

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Click Next
Select I accept the License

Agreement
Click Next

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Select I accept the License
Agreement
Click Next
Click Next

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Click Finish
Click Restart
Connect the USB cable.

and check in the Device
Manager if UNITROL 1000 is
listed under Ports
3 PC Firewall Configuration
Click Start – Settings – Network
Connections – Change
Windows Firewall Settings
Click the tab Exceptions and

Add Port

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Fill out Name: Scanning
and
Port: 5002
Do the same for Port 5003

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6.4.4 Starting with CMT1000
The CMT1000 communicates with the AVR via USB or Ethernet. .For more information
about the hardware connections refer to Chapter 3.3.9 Communication Ports. Start the
CMT1000 V6.310 application from Start-Programs
or from the desktop shortcut
6.4.4.1 Configuring the Port Interface (CMT1000 configuration)
Before the communication with

the AVR can be established, the
connection type should be set in
the CMT1000. The connection
type is specified using the Port
Configuration window, which
can be accessed from the main
window of the CMT1000 (Figure
6-4). Figure 6-4 Port Configuration.
Connection over a USB port from the PC (no Ethernet)
1. Connect via the USB port from the PC.

Select the "Serial" tab (1) first. See
Figure 6-5
2. Click the Ok button (2) to save the
changes or Cancel to abort the
configuration.
Figure 6-5 USB COM Port Configuration.
If the respective COM port is not found, check whether the required COMx is correctly
configured in the operating system or is being used by another application.
Port settings normally used for COM:
Base I/O Port address: 3f8
Interrupt Request Line (IRQ): 4

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Connection over an Ethernet port from the PC (TCP / IP)
1. To connect to the AVR using a

TCP/IP connection, select the
"TCP/IP" tab first. See Figure 6-6.
2. Fill out the IP Address of the remote
terminal in the Remote IP Address
field and click Enter on the keyboard.
A pinging process should be
automatically started to check
whether the remote terminal can be
reached using MODBUS TCP.
After a couple of seconds the pinging
process should be finished and a
message is displayed whether the
remote terminal could be reached or
not.
The message "Connection Ok"
indicates that the remote terminal
could be reached and that the
connection is Ok. In case the
message "Not accessible" shows up,
check whether the Ethernet, gateway, Figure 6-6 Remote IP Address Configuration.
firewall and/or cabling are correctly
configured and installed. For
configuration refer to Chapter 3.3.9
3. The pinging process is repeated periodically and it should start a couple of seconds after
displaying the last message. The message "Connection Ok" indicates that the remote
terminal could be reached and that the connection is Ok. In case the message "Not
accessible" shows up, check whether the Ethernet, gateway, firewall and/or cabling are
correctly configured and installed. For configuration refer to Chapter 3.3.9
The pinging process is repeated periodically and it should start a couple of seconds after
displaying the last message.
4. Click the Ok button to save the configuration or Cancel to abort the changes.
Note: The message "In use" can appear when the IP address is already being used by
CMT1000. This message can be ignored.

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6.4.4.2 Communicating with the AVR
Once the port connection is

configured, the CMT1000 performs
a scanning process to detect the
AVR over the interface selected
(USB or Ethernet). During the
scanning time (few seconds) the
access levels (Control and Monitor)
cannot be changed. Figure 6-7 CMT1000 during AVR Scanning Process
As soon as an AVR is detected, the

CMT1000 displays the AVR-ID and
channel identification (Main or
Redundant). The access level/type
is controlled by the green slide bar
and can now be used to change to
Monitor or Control Access. When
the CMT1000 is in Offline, most Figure 6-8 CMT1000 during Offline
parameters are read from the
computer memory, only the
information shown in the main
window is read from the device.
As long as the CMT1000 has Monitor or Control Access, the main window looks as in
Figure 6-9 and Figure 6-10. In this case all parameters accessed through the menus are
read from the device.
A green LED (“EEPROM”) on the
right side of the window indicates
whether all parameters in the RAM
are stored in the non-volatile
memory of the device or not. The
LED is lit (green) when all
parameter values match the ones
stored in the EEPROM memory. Figure 6-9 CMT1000 during Monitor Access
If the LED is dark, at least one

parameter has been modified and
its value will be lost after restarting
the device.
To store all parameters in the
EEPROM using CMT1000, click
"Write parameters to EEPROM"
from the File menu. Figure 6-10 CMT1000 during Control Access

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AVR scanning process failure: "Link Not Found"
The CMT1000 scanning process

can last up to one minute before
the AVR is detected; especially if
connection type is Ethernet. If no
AVR is detected by that time, the
message "Link Not Found" will be
shown in the main window (Figure
6-11). Check if the AVR is truly Figure 6-11 LinkNotFound message when the AVR
connected by verifying the cannot be found or the communication port cannot be
configuration and/or the hardware. accessed by the CMT1000
Even after the message "Link Not

Found" has been displayed, the
CMT1000 continues the scanning
process in the background until
the AVR is found.
For details about the configuration
refer to 3.3.9.1 USB Interface.
6.4.5 Menu Structure of CMT1000
The main window of the CMT1000 is shown in Figure 6-12 and is the starting point to access
all software features. The software features are accessed from the menu and each menu
item is grouped according to functionality.
 File: Load/save parameters

and enable optional SW.
 Monitor: Online measuring
 Setup: Set parameters
 Communication: Set IDs /
Ports / MODBUS
 Tune: Tune regulator
 Help: Software information Figure 6-12 Main Window of CMT1000
The following sections describe the CMT1000 menu organization and window contents.
IMPORTANT!
All software windows shown in this User Manual were taken with
standard style of Microsoft Windows (R) XP and most of them can be
closed by using the mouse and clicking on the cross in the upper right
corner. If the cross button is not available, the information in the window
explains how to close it. This is the case for “About CMT1000” which
can be opened using the menu “Help”.

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6.4.5.1 Help Menu
SW Update
Software and AVR Information
About CMT1000
AVR S/N: Unit’s serial number
Control: DSP software version
MCU: Panel software version
SW Revision: CMT1000 version
Configuration: ABB or Custom
Click on the window to close it.
Note: the serial number of the AVR is
shown in the window of and it should
be provided when an optional software
is requested from ABB.
Figure 6-13 About CMT Window
6.4.5.2 File Menu
*. ini (see warning message below)

saves the parameters to the PC hard disk
saves the parameters to an XML File
saves the parameters to the device’s EEPROM
user defined application

enables SW optional features (password required)
closes the application
Open Parameter File

A set of parameters values, previously stored in a so-called Configuration INI file, can be
downloaded to the AVR by using the option Open Parameter File from the CMT1000
menu. In order to download parameters to the AVR, make sure that the CMT1000 has
Control Access before trying to use the Open Parameter File option. The Configuration INI
file can also be opened when OFFLINE, in order to verify the values of the parameters,
prior to downloading them to the AVR.
The Configuration INI file should be compatible and previously created with CMT1000
release 5.xxx, otherwise a warning message may show up. Additionally, a message
indicating writing failure can appear after continuing the download of the incompatible
configuration INI file, when it contains at least one parameter value out of the permitted
range of selection.
The download of an incompatible configuration INI file is not recommended and it is up to
the user to verify if all parameters are set correctly before going into Operation with the
AVR.

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While the parameters are downloading, a warning
message may appear if at least one optional SW
is marked as activated in the INI file but is not
available in the AVR (Figure 6-14).
The warning window (Figure 6-14) also shows a
list of all optional SW which is activated according
to the INI file but which is not available in the
AVR. These will only be activated in the AVR, Figure 6-14 A warning message is
when they have been enabled (available) using shown when one or more optional
the SW Options tool from the CMT1000. SW is set as active in the INI file but
not available in the AVR.
Save Parameter File

The parameter values can be stored in a configuration INI file to the PC hard disk, for
further download to one or more AVRs (i.e. during commissioning) or for use as a
reference parameter file. A configuration INI file can be downloaded to a UN1020 AVR by
using the command "Open Parameter File".
When "Save Parameter File" is executed during Offline, it allows the user to create a
preconfigured file for further download to one or more AVRs. Once the CMT1000 is
started, all parameters are normally set to default values and they can be modified when
Offline. After they have been modified and the command "Save Parameter File" is
selected, all parameter values are stored in an INI file whose name is specified by the user
during the file creation process. The resulting INI file can be downloaded to an AVR using
the command "Open Parameter File".
When "Save Parameter File" is executed during Monitor or Control mode, all parameter
values written in the configuration INI file are read directly from the connected AVR; i.e. the
created INI file reflects the actual configuration of the AVR. During Monitor or Control
mode, this command can be used when a device must be replaced by a spare unit.
IMPORTANT!
A parameter *.INI file can be opened and read with a common text
editor and without the CMT1000 tool.
However, modifying a *.INI file by directly writing-in with a text editor

may lead to the complete inoperability of the parameters file. The
CMT1000 may not be able to correctly read the file any longer and
serious damage may be caused to the equipment due to the incorrect
parameter settings.
Please open an *.INI file using the CMT1000 all the time, when a
parameter value has to be changed.

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Customer Setup
Option for user-defined application
and OEM customers (password
protected).
SW-Options
It allows the user to enable (unblock) optional software in the AVR. A password code is
required for each specific function (SW-option) and it shall be ordered with ABB.
The following steps should be

followed in order to enable optional
software in the UN1020:
1. Make sure the CMT1000 has

Control Access (Figure 6-15).
2. Type the password provided by Figure 6-15 CMT1000 must have Control Access before
ABB (case sensitive) in the enabling optional SW.
white box located beside the
SW-option intended to enable
(Figure 6-16). Click the Enter
key on the keyboard in order to
validate the password.
A couple of seconds after

clicking Enter, the oval button at
the right side of the white box
should not be shaded anymore.
Check the password spelling if
this is not the case.
The behavior rules for the SW
activation buttons are shown in
Figure 6-17.
3. Once the oval button becomes

clear, click the button once.
After a few seconds the LED on
the button should be bright,
indicating the optional SW is

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now enabled.
4. After the oval button is lit click

the button “Save to EEPROM“,
to make the change permanent
even after restarting the device.
5. In the CMT1000 main window,

click in File and then, in "Write
Parameters to EEPROM".
6. Restart the device.
7. After the unit is powered up,

check if the SW-Option remains
enabled. If not, repeat the
procedure starting by Step 1.
Figure 6-16.The SW Options window allows

the user to enable optional software in the
AVR.
Figure 6-17 Upper: LED is bright when the

optional SW is enabled in the AVR. Lower: A
wrong password does not enable the SW.

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Close
Exit the CMT1000 software.
6.4.5.3 Monitor Menu
Measurements
Monitor \ Measurements
 Network Voltage (UNet) [% and kV]
 Machine Voltage (UM) [% and kV]
 Machine Real Power (P) [% and kW]
 Excitation Current (Ie) [A]
 Machine Current (IM2) [% and A]
 Machine Reactive Power (Q) [% and kVar]
 Network Frequency (fNet) [Hz]
 Machine Frequency (fM) [Hz]
 Power Factor (PF) --

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Figure 6-18 Measurements window

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Oscilloscope
Monitor \ Oscilloscope
Measurements and transients can be visualized, analyzed and stored to the hard disk
using the Oscilloscope tool of CMT1000. Up to 6 different measurement channels can be
visualized simultaneously on the black box of the Oscilloscope window (see Figure 6-19).
The signal or measurement to be displayed is configured on the right end side of the
Oscilloscope window with the options shown in Figure 6-19.
The Buffer Length defines the length of the buffer size used to record the transient data
and displays them on the black box of the Oscilloscope. The selection can be performed at
predefined values: 1, 2, 5, 10, 20, 50, 100 and higher up to 500 seconds. Each time the
Buffer Length value is changed by the user, the black box is resized in order to match with
the new value selected. The transient shown on the black box can be stored to the hard
disk afterwards; the transient data that could already pass-through the black box and is not
shown anymore, is lost (there is no additional memory or buffer).
When a set of consecutive data measurements is received with errors (i.e. due to cabling
or communication problems), the Out of Frame LED indication lights up. Under these
circumstances it is recommended to check the cabling and configuration between
CMT1000 and UN1020, in order to solve the problem. During the Out of Frame indication,
the Oscilloscope freezes and displays the last correct (error-free) measurement for each
channel, until the failure is resolved.
Figure 6-19 Oscilloscope window.
The Oscilloscope window menu and the function description of each item are explained in
Figure 6-20. The Oscilloscope can be started and stopped as explained in Figure 6-21.

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Open a previously stored waveform (ASCII table or *.xls)

Open a custom settings file for the Oscilloscope (*.cfg)
Save the current waveform to an ASCII file

Save the current Oscilloscope settings to a file (*.cfg)
Save the current waveform to a BMP format file
Export the current waveform to IEEE Comtrade
Shows / hides cursors (shown on the left side of the screen).

Plays the stored recording using the cursor A.
Figure 6-20 Menu structure of the Oscilloscope tool window and function
of each item.
Start: Starts the Oscilloscope: reading and displaying the measurements on screen.
The menu item changes its name after click on it.
Freeze Waveform: Stops the Oscilloscope: stops data reading and freeze transients.
The menu item change its name after click on it.
Figure 6-21 The Oscilloscope is started and stopped using the "Start" /
"Freeze Waveform" button located in the menu of the window.
IMPORTANT!
Previous waveform files saved with CMT1000 releases 3.xxx or 5.xxx
are not compatible with CMT1000 release 6.xxx.
Use the appropriate version of CMT1000 to open waveform files older
than release 5.xxx
Evaluation of the Waveform

Instantaneous values from transients can be observed using the cursors feature of the
Oscilloscope (menu Edit > Cursors).
As long as the cursors are enabled (Edit > Cursors), the two pointers or cursors A and B
are shown in the black box of the Oscilloscope with their standard configuration options, as
shown in Figure 6-22. The cursors can be moved with the mouse (click + hold + drag)
along the curve of the transient from the Channel they are configured. When the cursors
are moved, the user can see the instantaneous value of the curve at the time (dt) where
they are placed (Figure 6-22). If the instantaneous value from another Channel is object of
interest, the channel selection for the cursors A and/or B can be changed on the
Oscilloscope window itself (see Figure 6-22).

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The temporal buffer of the UN1020 can be used for troubleshooting by allowing retrieval of
data history recorded during the AVR operation time. As long as the CMT1000 is Offline,
the cursor A can be used to observe measurements and data stored on the temporary
buffer but on the Instrument windows. When instruments such as Measurements, Setpoint
Adjust, PQ Monitor and/or others are open when the cursor A is displaced along a curve in
the Oscilloscope window, the Instruments will show measurements reading from the AVR
at the time the temporal buffer was recorded (Figure 6-22). This additional information is
also stored in the temporary buffer but (some of them) are not shown in the Oscilloscope
window.
Notice that the cursors moved along the temporary buffer will show historical data on the
Instrument only if the CMT1000 is Offline; otherwise the Instruments show actual
measurements and reading from the AVR (and the system).
Figure 6-22 Evaluation of a waveform
A feature called Sweep Buffer can be used to displace the cursor A along the transient
curve at real time speed, and so, to observe the variations of measurements and data as
they might have been gathered during operation of the AVR.
When Sweep Buffer is enabled from the menu, a vertical line replaces the pointer A and
runs along the transient curve starting from the cursor A until the end of the transient at
real time speed (i.e. one second of cursor movement is equal to one second of operation
with the AVR). During the time the vertical line runs, the instantaneous value of the curve
is displayed on the Oscilloscope window, under the cursor A information. If an Instrument
window is opened during this process, the instantaneous data is also updated and shown

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in the window. The Sweep Buffer should be used together with the Instruments windows,
and therefore, it is only available when the CMT1000 is Offline. It can only be activated
from the menu when the cursors were already enabled as well.
Examples
a) During OFF LINE: previously stored waveform files

File \ Open Waveform: Open stored waveform file.
Adjust the Buffer Length if necessary to see the full
transient on the Oscilloscope.
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.
b) During MONITOR or CONTROL: Real time data

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.
Notes
 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, 2, 5, 10, 20, 50, 100 and higher values
up to 500 seconds.
 The time scale can be adjusted in the bar above the waveform (Zoom).

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Monitor \ Oscilloscope, Status Display
There are 4 analog signals that represent status changes on the oscilloscope. The
decoding of those signals is explained as follows:
Generator Control Mode:

0 = Auto
1 = Var
2 = PF
3 = Manual
4 = Open Loop
5 = VDC
6 = Sync
7 = Standby
Combined Limit:
0 = None
1 = Minimum Excitation Current Limiter active (Min Ie)
2 = Minimum Machine Voltage Limiter active (Min UM
3 = Minimum Iq Limiter active (Min Iq)
4 = Maximum Excitation Current Limiter active (Max Ie)
5 = Maximum Machine Voltage Limiter active (Max UM)
6 = Reserved
7 = Maximum Machine Current Limiter active (Max IM)
+8 = V/Hz Limiter active
+16 = Minimum Setpoint reached
+32 = Maximum Setpoint reached
Excitation ON active: Combined Limit = See values above
Excitation ON not active: Combined Limit = -1.0
GenState (Generator State):

0 = Idle (NoLoad)
1 = Change NoLoad -> Primary Net
2 = Primary Net
3 = Change Primary Net <-> Secondary Net
4 = Secondary Net
5 = Change Secondary Net -> NoLoad
6 = Primary Net or Secondary Net -> Grid ON
7 = Grid ON
8 = Grid ON -> Primary Net or Secondary Net
AlarmTripStatus:
0 = None
+ 1 = SW Alarm active
+ 2 = FCB Alarm active
+ 4 = External Alarm active
+ 8 = Modbus Communication Alarm active
+ 16 = Diode Alarm active (requires RDM SW)
+ 32 = Diode Trip active (requires RDM SW)
+ 64 = Supervision Alarm active (requires Double Channel SW)
+128 = Supervision Trip active (requires Double Channel SW)
+256 = DCH SwitchOver active (requires Double Channel SW)

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Combined Limit
Max UM Active + V/Hz 13.0
Max Ie Active + V/Hz 12.0
Min Iq 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

+8
Max Ie Active 4.0
Min Iq Active 3.0
Min UM Active 2.0
Min Ie Active 1.0 s
None
Figure 6-23 Example of Combined Limit Status
PQ Diagram (Power Chart)

Monitor \ PQ Diagram
Note: The Limiter points can be moved with the cursor.
Synchronization Diagram, Synchroscope

Monitor \ Sync Diagram

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IM or Ie Temperature Monitor
Monitor \ Temp Influence
IM Limiter
Ie Limiter

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Second Channel Measurements
Displays status and measurements from the Second Channel. Double Channel SW is
required to show this window; otherwise it is not accessible from the CMT1000 menu.
1. Displays the current

measurements of UNET, UM,
Excitation Current and
Machine Current from the
second channel.
2. Displays the current status

(Active or Standby) and the
current operating mode
(Auto, Standby, etc.) of the
second channel.
Example
3. Displays Alarm and Trip

statuses of the second
channel. The LED(s) are lit
(light red) when the signal
Figure 6-24 Second Channel Measurements window, when
is active (logical 1).
Double Channel communication over CAN is OK (data is being
4. Indicates the received correctly)
communication quality of
the CAN communication for
DCH software. The LED is
lit (light green as the
picture shows) during the
time the CAN
communication is enabled,
established between both
channels and the data free
of errors (i.e. no CRC
errors on data packets).
The complete Second

Channel Measurements
window becomes shaded if
the Double Channel
Comm. Ok LED is dark
(Figure 6-25) This means
that no valid data is
transmitted between both
channels and that data is
irrelevant to be displayed. Figure 6-25 Second Channel Measurements, when Double
Channel communication failed or is disabled.
Data Logger

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Max 10 data logs are stored

on non-volatile memory on
the target triggered by
configured events. All
available data logs are
listed.
Opening a log file goes

faster when in Monitor Mode
Event Monitor
Events are stored to the

target and periodically listed.
Complete list can be stored

on PC as a text file
Filters can be set to give a

better view on certain
events
Freeze button stops

periodical update in order to
evaluate the received
events.
The UNITROL device can

store max 500 events.
CMT1000 can store up to
1000 events, when
connected to the UNITROL
device.

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6.4.6 Setup Menu
Configuration of system data parameters

Soft start ramp parameters
Field flashing configuration
Limiters configuration
Setpoint configuration
VDC software configuration
Digital Input / Output configuration
Analog inputs configuration
Analog outputs configuration
Synchronization parameters
Rotating Diode Monitoring settings
Power System Stabilizer parameters
Monitor and Protection
Set AVR Date and time
Data Logger Setup
V / Hz limiter configuration
PQ, UM, IM and Ie limiter configuration
Line short circuit support
IM and Ie temperature monitor
Auto mode setpoint configuration

PF mode setpoint configuration
VAR mode setpoint configuration
Manual mode setpoint configuration
Open Loop mode setpoint configuration
Note: Some menu items may not be accessible when the CMT1000 has Monitor or
Control Access and/or the AVR has optional software which is not available. All menu
items are accessible when the CMT is Offline.

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6.4.6.1 Operational parameters
Adjust System Data

Setup \ System Data
Configure Soft Start

Setup \ Soft Start
Adjust Field Flashing

Setup \ Field Flashing

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Adjust V/Hz Limiter
Setup \ Limiters \ V/Hz
Limiter
Operational Limits. Adjust Ie, UM, PQ and IM Limiter

Setup \ Limiters \ Operational Limits
Excitation current (Ie) limiter

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Machine voltage (UM) limiter
PQ limiter and machine current (IM) limiters
Adjust Short Circuit Support

Setup \ Limiters \ Boost
Boost
Threshold % applies for both Boost and Voltage
Relay features. Boost and Voltage Relay cannot
be configured with different threshold values.
FRT detection (Fault ride through)

Setup for FRT detection output

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Adjust Limiters Temperature
Influence
Setup \ Limiters \ Temp
Influence
IM and Ie nominal values can

be changed in System Data
window.
Adjust Setpoint Range new window

Initial SP refers to the Initial setpoint of the operation mode.
Setup \ Setpoints \ Auto

The Initial Setpoint (SP) of Auto
mode is the final value of the Soft
Start ramp. For more information
refer to Chapter 3.4.2.1 Soft Start.
1. Parameter configuration: "SYNC
DisableCBCheck".
For more information see Chapter
3.4.2.7 Synchronization (SYNC)
2. Parameter configuration: "Enable
PF/VAR initial setpoint” will set SP
to initial value in case PF/VAR is
preselected when changing to grid False (default)
1
parallel operation. True
3. Parameter configuration: "Loose
grid go to initial SP” will set SP to
initial value when going to island
operation.
4. Parameter configuration: "Reset
SP to initial SP” will set SP to initial
value in case “Reset Setpoint” is
activated.

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Setup \ Setpoints \ PF
Setup \ Setpoints \ Var
Setup \ Setpoints \ Manual
Setup \ Setpoints \ Open Loop
Adjust Voltage Droop Compensation

Control Range
Setup \ Voltage Droop Compensation
Setup Window for busbar configuration

Setup Window for ring configuration
For configuration refer to Chapter

3.4.3.1 Voltage Droop Compensation
(VDC).

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6.4.6.2 IO configuration
Configure Digital I/O

Setup \ Digital I/Os

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Example of configuration of the input signals with the CMT1000 software tool
1. Select the analog input AI1 2. Select one or two digital signals
(or AI2 or AI3) and adjust the DI13 from +AI
input range [Setup \ Analog DI114 from –AI
Inputs] [Setup \ Digital I/Os]
Range : Uin0% = 2.0 V

Uin100% = 5.0 V
When using AI pins for DI signals, both inputs should not simultaneously be active.
Example of parameter setting using CMT1000
Example: Assigning
Parallel with Grid Status to
input DI10
Make Control-connection
to the unit
1
Menu bar CMT1000, start
menu
1. Select setup and then

Digital I/Os

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2. Open input DI10 by

clicking on the white
box.
3. Select input: "Parallel

with Grid Status"
4. Result: DI10 configured 4
The procedure above only changes the parameters in the volatile memory.
To make the modification permanent (even after restarting the AVR), all the parameters
have to be stored in the non-volatile EEPROM.
Save parameters during CONTROL Access:

- Unit: Menu bar CMT1000 \ File \ Write Parameters to EEPROM
- Hard disk: Menu bar CMT1000 \ File \ Save Parameter File

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Configure Analog Inputs
Setup \ Analog Inputs

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Configure Analog Outputs

Setup \ Analog Outputs
6.4.6.3 Miscellaneous Functions
Adjust Synchronization
Setup \ Synchronization
The window is shown if CMT1000 is

OFFLINE and/or Synchronization SW
(optional) is available in the device.

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Adjust Diode Monitoring
Setup \ Diode Monitoring
The window is shown when the CMT1000

is OFFLINE and/or the Rotating Diode
Monitor SW (optional) is available in the
device.
Adjust PSS
Setup \ PSS
The window is shown when the CMT1000 is OFFLINE and/or the Power System
Stabilizer SW (optional) is available in the device.
This window below can only be opened when the device is online and connected. Only
then both configurable test points can be monitored in the CMT oscilloscope.

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PSS Test Interface

a. The operator switches on/off PSS input signals and injections points
b. The operator selects two test points from the range TP1 … TP16
Both selected signals are shown in the CMT1000 Oscilloscope and are routed to the
analog output
c. The operator adjusts the analog output amplitude
l-shift (0 to 7) is equal to a factor of 2 (I-sift)
Eg. If l-shift equals 2, the analog output is multiplied by factor 4
Scaling of TP can be seen in the table below.
The analog output range can be configured with min (-10V to +10V) and max (-10V to +10V) values
which represent the scaling. All values represent peak values.
TP Signal Name Scaling I-shift

1 Frequency meausurement input ±12.5% 0
2 Frequency washout input ±12.5% 0
3 Frequency washout output ±12.5% 0
4 Ramp Track filter output ±25.0% 1
5 Power Input ±200% 4
6 Power washout input ±200% 4
7 Delta Power integrator output ±25.0% 1
8 Lead lag input ±25.0% 1
9 Lead lag output ±25.0% 1
10 Lead lag output limited ±25.0% 1
11 PID output ±100.0% 3
12 PID output limited ±50.0% 2

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TP Signal Name Scaling I-shift
13 Frequency injection point ±12.5% 0
14 Power injection point ±200% 4
15 LeadLag injection point ±12.5% 1
16 PSS Status bits 0
Bit 0: PSS selected

Bit 1: PSS active (contributing)
Bit 2: PSS blocked by Power
Bit 3: PSS blocked by Voltage lever
Bit 4: PSS blocked by frequency gradient
In order to get normalized gain for the measuring transfer function using analog outputs, the I-shift
parameter must be used. The table above shows a possible setup of the I-shift parameter in order to
get normalized gains.
If multiple machines are connected to the same step-up transformer, the user can apply a common
step command to all AVRs simultaneously. This allows testing the PSS and measuring more clearly
the increased damping with a step response.
The user has to enable the common step at all AVRs. The command is given only at one AVR and
is distributed over RS-485 lines to all other AVRs. A common step on all machines is applied within
1ms.
Below extract shows how the common step can be enabled.
During the time this is enabled, the VDC communication will be disabled
If the Common Step Enable button is selected, this status is shown in the setpoint adjust window
(indication turns green).

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The common step function is disabled as soon as the mode is changed or the excitation is switched
off.

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Monitor and Protection Configuration
Setup \ Monitor and Protection
The window can only be accessed when Offline or when Double Channel (optional) software
is available in the AVR. For more information about the configuration refer to Chapter 3.4.4.4
Double Channel (DCH).
LEDs signalization Trip DO outputs zero (logical) during Standby.

All LEDs including DCH Comm.Ok
Trip DO outputs Trip Status during Standby .
Signal inactive, i.e. logical ze ro.
Alarm DO outputs zero (logical) during Standby.
Signal a ctive, i.e. logical one.
Alarm DO outputs Alarm Status during Standby.
Configuration Matrix settings

Monitoring function does not trigger Trip.
Monitoring function triggers Trip.
Monitoring function does not trigger Alarm.

Monitoring
Function Name Monitoring function triggers Alarm.
Output status of Latch memory status of the monitoring function (latched to one
the monitoring when the Output status changes from zero-to-one).
function. The Latch status is used as input for the Configuration Matrix.

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AVR Date and Time

Setup \ AVR Time and Date
Adjust the time by means of the lower and raise buttons, then click Set AVR time
Set AVR to PC time: Click this button and the AVR will show the same time as in
Windows.
Data Logger
The Data Logger Setup can adjust
1 Sampling rate
2 Pre-Trigger value
3 Source
3 Extended Signal
The 7 basic signals are not listed, they are always active
 Generator Voltage
 Generator Current
 Reactive Power
 Excitation Current
 PWM
 Generator Status
 Generator Operation Mode

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1 Sampling
Rate

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2 Source

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3 Extended
Signals

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6.4.7 Communication Menu
Set AVR-ID (VDC) and the Channel Identification (DCH)

Configuration of serial COM port or TCP/IP address
Set MODBUS configuration for Remote Access
Monitoring tool for VDC
Protection against changing parameters
ID Definition (AVR-ID & DCH)

Communication \ ID Definition
Configuration window for AVR-ID (VDC) and
Channel Identification (Double Channel).
2
1. AVR-ID should be configured before the
use of VDC. For more information refer to
Chapter 3.4.3.1 Voltage Droop
Compensation (VDC). 1
2. Channel Identification should be

configured before using Changeover and
Follow-up from the Double Channel
feature. The chosen selection, Main or
Redundant, is displayed in the main
window of the CMT1000 (and panel) even
if the Double Channel feature is not
available in the AVR.
If the Double Channel feature is not used,

the channel identification can be changed
without affecting other UN1020 functions
with the exception of the Modbus ID,
which is used for CMT1000 access. That
allows changing the name displayed in
the CMT1000 and panel. For more
information refer to Chapter 3.4.6 Modbus
for Remote Access

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Port configuration
Communication \ Port configuration \ Serial
Configures the connection interface with the

AVR. For more information refer to Chapter
6.4.4.1 Configuring the Port Interface.
Communication \ Port configuration\TCP/IP

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MODBUS configuration (RS485)

Communication \ MODBUS Supervision \ Remote Access
The MODBUS Slave-ID is the same used for MODBUS RS485. For configuration refer to
Chapter 3.4.6 Modbus for Remote Access.
Keep-alive action
Configuration parameters for RS485 comm unication ONLY.
Protocol Bit rate (b/s)
Character frame
Active
MODBUS over RS485 not active. VDC can be activated.
MODBUS over RS485 active. VDC should not be activated.

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Communication \ MODBUS Supervision \
Monitoring
Do not use the ID displayed here

Please be aware that this number will be automatically
adjusted according the AVR-ID number and the Channel
Indentification (Main / Redundant)
Communication \ MODBUS Supervision \

Channel Setup

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VDC Monitor
Communication \ VDC Monitor
VDC Monitor is a tool to analyze the VDC communication between the AVRs connected to the
same RS485 bus. The VDC communication should be enabled before using this tool.
1. Displays the AVR-ID number

and the actual compensation
used for regulation. The
compensation value will only 1
be used when the AVR is 2
operating in VDC mode. 3
2. Each LED number = the AVR-
ID 1 to 31 for each AVR
connected to the RS-485 bus.
A LED is lit when valid (error
4
free) VDC data packets are
being received from the AVR
whose AVR-ID matches the
LED number.
The LEDs indication is useful
for troubleshooting problems
when using VDC.
Green:
Q sharing on same bus
Yellow:
Q sharing on different bus
Red:
AVR is forced to AUTO
3. It selects the AVR-ID (or
LED) of the AVR from
which specific (Net ID, IM
Nominal and Iq rel) has to
be displayed.
4. This is the information displayed after the user selects an AVR-ID using the selector
explained in Item 3 (above).
All data displayed is real-time data. The Net ID shows Primary or Secondary Net
numbers according to the current status of the AVR. A special case applies if Net ID is
equal to zero, which means that the VDC data packets had communication errors or the
data packets from this particular AVR-ID are not being received at all. During the time
Net ID = 0, the LED for this AVR-ID is shown dark.
IM Nominal refers to the Nominal Machine Current and Iq Rel to the Reactive Current in
p.u. units.

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Control Password
In order to protect parameter changes by unauthorized persons, the customer can define
passwords to enter CONTROL mode to change parameters.
When hash is 1...9999, CMT will ask for a password before going to CONTROL mode. 0
means no password.
Setting for password, range 0 to 9999
0000 No password is active / default
4783 Default password, will work independently of any setting
Password will be asked when changing CMT from MONITOR to CONTROL mode. The
password is active for 10min
When CMT runs in MONITOR

mode, the password setting field
is grayed out.
When CMT runs in CONTROL
mode password can be set
6.4.8 Tune Menu
Adjust Setpoint, Trigger Setpoint, Status Displays

Tune \ Setpoint Adjust
It allows setpoint adjustment, step response tests and visualization of operating
modes, generator states, limiters and alarms status.

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1. Displays the generator state condition, according to the Gen CB Closed and
Parallel with the Grid status signals. Prim. Net and Sec. Net are used during
VDC operation mode.
2. Displays the actual operating mode of the AVR. Some modes may be shaded
(disabled) if an optional feature is not available or due to system conditions or
configuration. For more information about the software feature and operation
modes refer to Chapter 3.4 Software.
3. Displays Limiters status.
4. Displays AVR Alarms status. Not all alarms statuses are shown when an
optional feature is not available in the AVR.
5. The actual setpoint can be adjusted with the upper Up and Down buttons (if
the adjustment is not performed via analog or digital inputs). A step response
can be performed by specifying the Step value and then clicking the lower Up
(actual setpoint + Step) and Down (actual setpoint – Step) buttons.

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Regulator Parameters AUTO
Tune \ Auto
Allows the parameter configuration of the PID

regulator to be used during AUTO mode and the Kq
Droop.
Expert Tuning:
In order to open the window, click Control+Shift+F9
when the Tune Auto window is active
For details on the field rotor limitation, refer to 3.4.4.3 Field Voltage Limiter.

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Regulator Parameters PF/VAR/PQ Limiter

Tune \ [ PF/VAR/PQ Limiter ]
Allows the configuration of parameters of the

PI regulator used during PF/VAR modes and
PQ Limiter.
Regulator Parameters Manual / Ie Limiter

Tune \ [ Manual/Ie Limiter ]
Allows the configuration of parameters of the PI

regulator used during Manual mode and Ie
Limiter.

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6.4.9 Help Menu
Help \ Firmware update
Click Load File and select the appropriate

*.abb file.
Newest version as of release date of this

manual:
Then click Update. It is possible to update

the Target SW from USB or Ethernet
(faster).
In the following pop-up click Continue:
The update process is started and will take

around three minutes.
Download successful
The download succeeded successfully if
following pop-up appears:
Click Ok.
If the programming completed successfully, disconnect the USB cable and power cycle
the device.
Connect the CMT1000 to the device and double-check the loaded target software version
against the CMT1000.
In all other cases, the download has failed.

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Proceed with following instructions.
1. Close all the pop-ups by clicking Continue

2. Disconnect the USB cable, after 5 seconds connect it again.
3. Go into CONTROL mode
4. Repeat the download
Help \ About CMT1000..
Shows SW and HW Revision and HW serial number
6.4.10 Save Parameter File
PC UNITROL 1010/1020
RAM EEPROM
Open Write
Parameter Parameters Parameters
Parameters
File to EEPROM
HARD
DISK Save
Parameter
File
EEPROM LED lights up, if data RAM = EEPROM (MONITOR or CONTROL only)

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6.4.10.1 Status during MONITOR or CONTROL
After switching from OFF LINE to MONITOR/CONTROL, CMT1000 reads the parameters
from the device‘s RAM. Now, all parameter changes carried out using CMT1000 are
written directly into the device‘s RAM.
- Write Parameters to EEPROM: The parameters in the RAM are stored in the device (only
possible during CONTROL Access).
- Save Parameter File: The parameters are saved to the hard disk as an INI file.
- Open Parameter File: The INI file is loaded into CMT1000 and the RAM is
overwritten again (only possible during CONTROL Access).
When opening a parameter file from disk, the old parameter file is immediately overwritten
in the RAM (only possible during CONTROL Access).
6.4.10.2 Status during OFF-LINE
No parameter changes carried out in CMT1000 are transferred into the device.
- Write Parameters to EEPROM: No effect, since there is no communication between

CMT1000 and the device.
- Save Parameter File: The parameters are saved to the hard disk as an INI file.
- Open Parameter File: The INI file is only loaded into CMT1000.
If you now switch to MONITOR or CONTROL the CMT1000 reads data from the RAM
again.
6.5 Additional Tools
In addition to the tool on the delivered CD, ABB recommends using following SW Tools,
which can be downloaded free of charge from the internet:
Software Tool Description URL

Notepad++ compares parameter files and http://notepad-plus-plus.org)
indicates differences
TOP enables viewing IEEE comtrade files http://www.pqsoft.com/top/
and doing overlays

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
Chapter 7 - Preventive Maintenance
7.1 General
NOTICE!
ABB recommends periodical training for the maintenance personnel.
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 1020 unit are to be touched and/or attached only with
caution.
7.3 Standard Procedures for Maintenance
When the system is at a standstill, the screwed terminals, which can get
loose due to vibrations, should be checked for tightness. Dusty cooling
flanges should also be cleaned.

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
Chapter 8 - Troubleshooting
8.1 General
Chapter 8 - Troubleshooting provides instructions to assist in localizing a

fault within the excitation system as a whole. However, it is not possible to
deal with all eventualities in full.
Before working on the excitation system the general safety instructions in

Chapter 2 - Safety Instructions must be read and understood.
8.3 List of Possible Faults
Possible causes Checks, action

Check operation of AVR, green LED must be
Machine is not excited
blinking and yellow LED must be on
Field circuit interrupted Check wiring for break
Field circuit-breaker does not 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 by the Measure auxiliary supply UAUX,
field flashing Measure power electronics supply UPWR
Check field flashing Off level
Machine is first excited then discharges again Check operating mode. For field flashing Auto is
normally used
Check field flashing Off level
Check setpoint
Measure power electronics supply UPWR
If all supplies and setpoints are correct, then
change the 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 (CMT1000, Monitor)
-> positive rising

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Chapter 8 - Troubleshooting 

Overvoltage during build-up Check Soft start settings with the oscilloscope
Overvoltage caused by voltage regulator Machine voltage UM present

Check system data
Check operating mode. For field flashing normally
Auto is used
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 Auto is

normally used
Check setpoints
Check parameters of Auto regulator
Setpoint error Higher, lower inputs unstable

External 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: reset regulator

No: check parameters of Auto and PF, Var
regulator

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 Chapter 8 - Troubleshooting

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

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 by
(normally protected by limiters) adjusting the setpoint.
Check setting of limiters
Regulator fault Measure output voltage at terminals 8, 9 (oscillos-

cope)
Measure voltage UPWM (CMT1000, 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 normally

Auto is used
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 normally
Auto is used
Check setpoint
Check parameters of Auto regulator

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Chapter 8 - Troubleshooting 

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 outputs Check configuration

is not correct
8.4 Repair
It is forbidden to open the plastic cover of the unit. A defective unit has to be sent in to
the return center for repair with a failure description and, if possible, trending of the
failure. Contact our return center prior to sending it to the manufacturer’s address. Note
that the manufacturer’s address may be different than the one specified by our return
process.
See manufacturer’s details on Chapter 1.5 Manufacturer’s Address.
8.5 Compatibility
Target Release PC Tools / CMT1000 Panel Release VDC

6.xxx CMT1000 Release 6.xxx OS 2.04, Control 1.001 No restrictions
Earlier versions of CMT1000 are no longer compatible with this AVR.

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
Chapter 9 - Technical Data
9.1 General
9.1.1 Ordering Information

Material description Order code
UNITROL 1020-0003 BASIC 3BHE030579R0003
UNITROL 1020-0006 FULL 3BHE030579R0006
UNITROL 1020-0007 FULL + PSS 3BHE030579R0007
UNITROL 1020 SCP door kit 3AUA0000013086 Order Text: OPMP-01-Kit : Mounting
Cabinet Panel ACS
UNITROL 1020 Cable to Panel 3BHE027825R0150 Ethernet Patch Cable, CAT5, RJ45,
Connector/connector, shielded,
Length: 150 cm
Color: Grey
External capacitor kit (E251846) 3BHE044230R0010 UN1020 Ext. Capacitor UR
9.1.2 Electrical Data of AVR UN1020:

Excitation Input (AC/DC) Voltage Regulation
AC Nominal voltage (sinusoidal) 0...250 V ac Accuracy @ 25 °C 0.2%
AC voltage (max, sinusoidal) 300 V ac Reaction time 20 ms
Frequency 40…600 Hz PWM limitation 0.5...99%
DC nominal voltage 0...300 V dc
Max. DC voltage 420 V dc Exciter Current Measurement
Max. peak voltage (non-sinusoidal) 420V peak Full range 0...40 A dc
Test voltage for 1 min 2.8 kV dc Accuracy after digital filter < 1 %
Resolution of sensor 808 mA
Auxiliary Power Supply Input (AC/DC) Sample rate 130 kS
3-ph AC Nominal voltage (sin.)(1 9…250 V ac Resolution after average filter 100 mA
1-ph AC Nominal voltage (sin.)(1 16…250 V ac
AC voltage (max, sinusoidal) 300 V ac Machine Voltage Measurement (5
Frequency 40…600 Hz Full range peak voltage against PE 500 Vp
DC nominal voltage (min/max)(1 18…300 V dc Full range voltage, (phase to phase) 600 V ac
Max. DC voltage 420 V dc Nominal voltage 3 x 450 V ac
Max. peak voltage (non-sinusoidal) 420V peak Input impedance 6.0 MOhm
Test voltage for 1 min 2.8 kV dc Test voltage for 1 min. 2.8 kV dc
Max power consumption 40 W Accuracy (4 (-40 to 70 °C / 25 °C) 1% / 0.1%
Resolution 245 mV rms
Excitation Output – Maximum Ratings
Continuous current at 55 °C 20 A Network Voltage Measurement
Continuous current at 70 °C 10 A Full range voltage 600 V ac
Maximum current for 10 sec 38 A Nominal voltage 1 x 450 V ac
Input impedance against PE 9.0 MOhm
Recommended Excitation Current Test voltage for 1 min 2.8 kV dc

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Chapter 9 - Technical Data 

3~ Phase Input (2 Accuracy (4 (-40 to 70 °C / 25 °C) 1% / 0.1%
Continuous current at 40 °C 20 A Resolution 440 mV rms
Continuous current at 55 °C 15 A / 20 A (3
Machine Current Measurement
Recommended Excitation Current Full range current 1A / 5A 2.8 / 13.4 A ac
1~ Phase Input (2 Nominal current 1 to 5 A ac
Continuous current at 40 °C 12 A / 20 A (3 Shunt resistor 10 mOhm
Continuous current at 55 °C 10 A / 15 A (3 Maximum current for 10 s 22 A rms
Maximum current for 1 s 38 A rms
Recommended Excitation Current Maximum current for 100 ms 54 A rms
DC Input (2 Common mode range 5 V p
Continuous current at 40 °C 20 A (3 Accuracy (4 (-40 to 70 °C / 25 °C) 1% / 0.1%
Continuous current at 55 °C 15 A /20 A (3 Resolution 0.2% of In
Impedance to Pe (not galvanically 500 Ohm
insulated from Pe)
IGBT with Free Wheeling Diode
Max. forward voltage of integrated
freewheeling diode (25 °C, IF = 30 A) 2.6 V
M.a.s.l. >1000m derating factor
Remarks
(1:Start voltage:
Load condition no load at Vdig 100 mA at Vdig

Ambient -40 °C 0 °C -40 °C 0 °C
Input
<0.5 Imax <4.0 A
DC 18 V dc 18 V dc 18 V dc 18 V dc
Ohm Pmax = 100 W
3 ph <0.5 Ohm 9 V ac 9 V ac 11 V ac 9 V ac
1ph <2.0 Ohm 30 V ac 16 V ac 55 V ac 24 V ac
(2: Excitation current can be raised by choosing improved cooling or mounting of an aluminum plate. Temperature
behavior is dependent on input voltage, single, three phase or DC input and its value as well as on the resistance
load of the exciter winding. Max heat sink temperature of 90 °C must not be exceeded. Please contact ABB for
further information.
(3: With external capacitor of 1 mF
Requirements:
Min. Voltage: >=450 V
Temp. Range: -40...85 °C
Oper. lifetime at 85: >5000h
Ripple curr. at 100Hz at 85: >5ª
ESR 20°C 100Hz: <120mOm
Recommended type: Manufacturer Evox Rifa PEH200TO4100M, PEH200YK410TM, PEH169YO4100M
(4: Frequency bandwidth: 10...200 Hz. Define the accuracy up to 150 Hz with 3% and up to 200 Hz with 10%
(5: Voltage measurement shall always be connected over potential transformers (PT’s)
In case Um > 250Vac, the star point of the secondary side must be connected to PE
PT configuration : Three phase (star point connected to PE)  Max nominal value 500Vac
Single phase / Three phase GN  Max nominal value 250Vac

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 Chapter 9 - Technical Data
Short time overcurrent capability for excitation output

Duration 3 sec 10 sec 20 sec 30 sec 1 min 2 min 5 min cont. units
Ambient Temp.
40 °C 38 38 34 32 26 25 24 20 A
55°C 38 38 34 30 25 24 22 20 A
60°C 38 36 32 24 20 18 16 15 A
65°C 36 34 26 20 16 15 13 12 A
70°C 34 30 20 16 14 12 11 10 A
Remark: After an overcurrent occurs, device must not be loaded again for 100 x the defined duration.
Electrical Data of Analog and Digital Input / Output (max. cable length 30m):
Analog Input Digital Inputs
Full range peak voltage 10 V Number of inputs 4
Input impedance 240 kOhm Input impedance to GND 2 kOhm
Common mode range 5 V GND reference PE
Accuracy < 1% Input voltage range 0…28 V
Resolution 10 mV Digital input thresholds (high / low) 13 V / 5 V
Analog Output Digital Inputs / Outputs

Full range peak voltage 10 V No. of configurable inputs / outputs 8
Max output current 10 mA Voltage range of 24 V supply 21...25 V
Output impedance 100 Ohm Maximum output current 24 V supply 600 mA
GND reference PE Input impedance (set as input) 1.65 kOhm
Accuracy < 1% GND reference PE
Input voltage range 0...28 V
Digital input thresholds (high / low) 13 V / 5 V
Max driver current (to GND) 150 mA
Electrical Data of Communication Interfaces:

Ethernet Interface CAN Interface
Data rate 10/100 MBit/s CAN_L / CAN_H signal level 0…5V
Maximal cable length 100m Data rate 500 kBit/s
Auto-MDIX Max cable length 30m
Auto-negotiation and Termination (configurable with
parallel detection Jumpers) 2 x 68 Ohm
Isolation to PE 1 kV dc Isolation to PE 1 kV dc
RS-485 Interface USB Service Interface

RX / TX signal level 5V Data rate 12 MBit/s
RS-485 bus Half duplex Max. cable length 3m
Data rate Configurable USB Version 1.0, 1.1, 2.0
Maximal cable length 500m
Termination (configurable with Service Control Panel
Jumpers) 120 Ohm Display resolution (pixel) 128 x 64
Isolation to PE 1 kV dc Max. cable length 3m
Connector RJ-45

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9.1.3 Environmental data of AVR UNITROL 1020:
Permission ambient Temperature Isolation Coordination
Storage temperature maximum 0°...55 °C IEC60664-1
Recommended storage temperature 25 °C
Operating temperature -40...70 °C cUL-Certification (CSA compliant)
Maximum heat sink temperature 90 °C UL 508, user group (ongoing)
File number E251846
Mechanical Stability
Vibration, IEC60068-2-6 DNV class B
Shock and bump, IEC 60255-21-2 Class 2 DNV Certification
Seismic, IEC 60255-21-3 Class 2
Housing
EMC Immunity Protection class of housing IP20
EN 61000-6-2 Pollution degree 3
(Generic immunity standard) Dimension, L x W 302 x 170 mm
Height 111.4 mm
EMC Emission Weight 3.8 kg
IEC 61000-6-4
(Generic emission standard)
9.1.4 UL Certification
To use UNITROL 1020 in a UL compliant way, the following must be considered:
Max. surrounding air temperature 70 °C

UNITROL 1010 max output capability at 70 °C 5 A /150 V
UNITROL 1020 max output capability at 70 °C 10 A /150 V
Only 60/75 °C wires shall be used
Marking for proper connections for the power supply, control, load
For use in Pollution Degree 2 Environment
Grounding conductor terminal shall be green-colored or plainly identified with “G”, “GRD”,
“GND”, “GRND”, “Ground”, “Grounding” or IEC Publication 417, Symbol 5019.
9.1.5 Reliability UNITROL 1020
MTBF (MIL-HDBK-217F) GB(40°) 22.8 years

Failure rate in time GB(40°) 5000 FIT
Operational life time of capacitors > 100’000 h

Average ambient temperature 40 °C
Input power 3 phases
Exciter current (without external cap) 15 A

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9.1.6 Battery life time information
A battery is installed inside the panel. The battery keeps the clock operating in memory during
power interruptions.
Expected lifetime of battery at 45 °C > 10 years
To remove the battery, use a coin to rotate the battery holder on the back of the control panel.
Replace the battery with type CR2032.
NOTICE!
The battery is NOT required for any control functions except for the
clock.
9.1.7 Mechanical data

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9.2 Settings Record for UNITROL 1020
Name and Address of Customer:
Plant:
Order No.:
Plant Schematic No.:
Device Identification:
Type Plate:
Delivery Date:
Software Revision: Control:
Panel:
CMT1000:
Remarks:
Place and Date of Commissioning:
Name: Company:

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9.3 Parameter Settings, Default Values
All parameter setting sand default values are described in the Modbus address table.

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Chapter 10 - Appendix 

Chapter 10 - Appendix
10.1 Documentation References
This User Manual is available in the following languages:

1. UNITROL 1020 User Manual 3BHS335648 E82
2. UNITROL 1020 Benutzerhandbuch 3BHS335648 D82
3. UNITROL 1020 Manuel d'Utilisation 3BHS335648 F82
4. UNITROL 1020 Manual de Usuario 3BHS335648 S82

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 Chapter 10 - Appendix
REVISION
Rev. Page (P), Description Date

ind. Chapt. (C) (or number of revision) Dept./ Init.
- First issue 2011 09 22
A Changes new Release 2011 10 10
B General changes and updates 2011 12 15
C Small changes in layout, review by several people 2012 01 25
D General changes and updates 2012 05 02
E Release 6.1 2013-05-17
F Release 6.2 2014-01-15
G Release 6.2 2014-02-14
H Release 6.3x 2016-03-24

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ABB code: 3AFP9155706 ver: B
System Description
UNITROL 1020
MAN Power Plant
AVR Plate
Single Channel
Based on Project
Prepared by Rudolf Moeckli 12.12.16

Approved by Sven Gentner 12.12.16 Responsible Department IAPG-E
Title System Description for UNITROL1020 MAN 1CH Power Plant system
Document number
Language Rev. ind. Page 1
ABB Switzerland Ltd 3BHS581347 E41 en C Number of
pages 15
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Contents
Contents ..................................................................................................................................................................... 2
1 Introduction ........................................................................................................................................................ 3
2 Modes of Operation ........................................................................................................................................... 4
3 Single Line .......................................................................................................................................................... 5
4 Layout ................................................................................................................................................................. 6
5 Operation ............................................................................................................................................................ 7
5.1 Alarm and trip indications .............................................................................................................................. 7
5.2 Control elements ........................................................................................................................................... 8
5.3 Power inputs .................................................................................................................................................. 8
5.3.1 Excitation power input 8
5.3.2 24VDC input, AVR control supply 8
5.4 System components ...................................................................................................................................... 9

6 Different AVR Plate Versions.......................................................................................................................... 10
6.1 Status information ....................................................................................................................................... 10
7 Technical Data.................................................................................................................................................. 12
7.1 Order information for MAN Plate and AVR type.......................................................................................... 12
7.2 General Technical Data............................................................................................................................... 12
7.3 Environmental data of the complete AVR plate .......................................................................................... 12
7.4 Conditions to be in line with UL 508A ......................................................................................................... 13
7.4.1 Disconnecting means for power supply 13
7.4.2 Wiring ratings 13
7.4.3 Terminal ratings 13
7.4.4 Cable duct specification 13
8 Labels ................................................................................................................................................................ 14
8.1 Label definition with reference to status ...................................................................................................... 14
8.2 UL 508A specific label ................................................................................................................................. 14
9 Revision History .............................................................................................................................................. 15
Document number Lang. Rev. ind. Sheet
ABB Switzerland Ltd 3BHS581347 E41 en C 2

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1 Introduction
This Document describes the single channel UNITROL 1020 system, designated as
Standard UNITROL 1020 system for MAN Power Plants.
The power for the excitation is supplied from shunt (an excitation transformer connected
to the machine stator terminals) or from PMG. Boosting for short-circuit support is provid-
ed by 3 current transformers (3 CTs).
Field current limiter for boosting is provided.
The main function of this system is to control the voltage of the generator. The main con-
trol interface takes place over Modbus TCP.
For further information refer to:
 3BHS335648 E80: UNITROL 1020 - User Manual
 3BHS581347 E20: UNITROL 1020 MAN 1CH Electrical Drawing,
including List of Terminals and List of Components
 3BHS581347 E01: UNITROL 1020 MAN 1CH Mechanical Layout
 3BHS581347 E31: UNITROL 1020 MAN 1CH Test report

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2 Modes of Operation
The system can operate in one of the following modes:
- Automatic voltage regulator (AUTO mode)
In automatic mode, the systems keep the generator voltage constant based on the
adjustment of the setpoint.
- Automatic Synchronizing Mode (Optional)
The automatic synchronization of a synchronous machine with the line is achieved
using the optional integrated synchronizing function.
In addition the optional digital input signals Voltage Increase and Voltage De-
crease can be used for external synchronization.
- PF/VAR control for net parallel operation
UNITROL 1020 offers a wide flexibility in net parallel operation, where control
takes place over Modbus TCB interface.
- Manual mode
The manual mode is a field current regulator. The manual mode can only be acti-
vated by the CMT1000 tool for commissioning or troubleshooting purposes.
MAN will control the UNITROL 1020 over Modbus, therefore hardwired IOs are limited.

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3 Single Line
Part of the electrical drawing 3BHS581347 E20 rev H:

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4 Layout
Mechanical Layout 3BHS581347 E01 rev E:
Dimension of the plate

- Width 425 mm
- Height 680 mm
- Depth 155 mm

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5 Operation
5.1 Alarm and trip indications
The system provides a digital trip output by a potential-free contact K03. If the trip signal
is activated, the system must be shut down at once by the overlaying control system.
Following monitor functions will trigger a trip:
 Any PT failures on UM such as
o Partial loss of UM
o Loss of UM
o UMLx Freeze
 Loss of Control
 Loss of Excitation
 Temperature limit of 85° is exceeded
 External Alarm (MCB Q11)
 Internal power fail
 Diode Trip
 Emergency Exc. Off (External trip input)
Alarms are indicated directly on the panel, the overlaying control system will get an indica-
tion over Modbus.
Following monitor functions will trigger an alarm:
 Loss of Remote Control (Modbus communication)
 Any measurement failures such as
o Unet Freeze
o IM2 Freeze
 Temperature Limit of 70° is exceeded
 Digital Output fail
 FCB Alarm
 Diode Alarm
 GCB Alarm
 AVR output SC
Any Alarm and Trip will be indicated at the panel and must be reset by activation of the
signal “Reset Alarm”. This can be done via the panel or via Modbus command.

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5.2 Control elements

The operating personnel must be familiar with the layout of the control and HMI as well as
with the effect of commands on the excitation system. Using these controls and HMI, the
operating personnel is in a position to adapt the generator via the internal control and
regulating circuits of the excitation system to the operating conditions of the power station
and/or of the network.
5.3 Power inputs

5.3.1 Excitation power input
Supply modes
The system supports any input voltage such as DC, 1-phase or 3-phase supply. Supply
source can be PMG, auxiliary winding, shunt or auxiliary supply to be used.
In case of shunt supply the CT compounding is compulsory, for all other supplies the
compounding CTs are not required, thus the terminal will stay unconnected.
Startup
If auxiliary winding or shunt supply is used, the generator must provide remanence volt-
age in order to start up excitation.
Field flashing
In addition, separate field flashing input is supported. The field flashing is controlled by the
UNITROL 1020 with the digital output “Voltage Relay” and is activated when the machine
voltage is below the set threshold regardless whether the excitation is active or not.
The input voltage for field flashing must be coordinated with no-load excitation voltage,
typically 24Vdc will be used.
5.3.2 24VDC input, AVR control supply

AVR control supply is taken from a separate 24V dc supply. In case 24V supply fails, the
excitation is switched off.

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5.4 System components

The system components as shown in figures above and the system’s electrical drawing
are shortly described in this clause:
G Synchronous Machine, in this case the Generator
E Exciter Machine
PTNET Potential Transformer
2CT, 3CT Current Transformer
GEN CB Generator Circuit breaker
PMG Permanent Magnet Generator.
-G10 Main channel UNITROL 1000 module
-C01 This an external capacitor for the main channel.
-K06 Boosting contactor. It connects the boosting 3 CTs to the field directly for
boosting. As soon as a drastic voltage drop is detected at the terminals of
the generator, the boosting CT is connected to the field to supply the exci-
tation current in order to avoid the generator trip due to loss of excitation.
-F02 This is a field current limiter, ECL-10. It is used to limit the boosting current
from the 3 CTs to the desired level.
-V01/02/03 These three diode bridges isolate the boosting and excitation circuits.
-K07 Relay to activate the field flashing supply.
-R01 4.7 Ohm resistor to limit field flashing current.
-V04/05 These two diodes bridges isolate the field flashing input and the excitation
supply.
-Q11 This is an MCB for the Main channels overcurrent protection.
-K11 The DC Field breaker for the main channel.
-K11.1 Auxiliary relay for the main DC Field breaker.
-R11 The Varistor for the DC Field breaker.
-K01 The Tripping relay for the DC Field breaker.
-K03 Relay with potential-free contact for providing the AVR TRIP output.
-K05 Relay with potential-free contact for providing the AVR Automatic Synchro-
nization release signal.
-K12 Relay for the external Emergency Excitation OFF input signal.
-U01 Optocoupler module for the external Voltage increase input signal.
-U02 Optocoupler module for the external Voltage decrease input signal.

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6 Different AVR Plate Versions

6.1 Status information
Status Description / New features / Limitations Released First
Date delivery
“-“ Design with Order Code 3BHE044620R610x
Manufacturing documents: 30.09.16 30.09.16
Electrical: 3BHS581347 E20 rev E
Layout: 3BHS581347 E01 rev B
Parameter File 3BHS581347 E23 rev -
Target SW: Release 6.313 (Beta)
New Features
 Initial Version
Known limitations
 None
“A“ Design with Order Code 3BHE044620R610x
Electrical: 3BHS581347 E20 rev F
Layout: 3BHS581347 E01 rev C
Parameter File 3BHS581347 E23 rev -
Target SW: Release 6.313
New Features
 Documentation update according to UL 508A
Known limitations
 None
“B“ Design with Order Code 3BHE044620R610x
Electrical: 3BHS581347 E20 rev G
Layout: 3BHS581347 E01 rev D
Parameter File 3BHS581347 E23 rev A
New Features
 new Input signals
Voltage Increase and Voltage Decrease
Known limitations
 None

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“B“ Design with Order Code 3BHE044620R610x

Electrical: 3BHS581347 E20 rev H
Layout: 3BHS581347 E01 rev E
Parameter File 3BHS581347 E23 rev A
New Features
 Additional X1-29 terminals for easier wiring of
external signals
Known limitations
 None

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7 Technical Data
7.1 Order information for MAN Plate and AVR type
AVR Plate Order code
UNITROL 1020 MAN Eng. 1CH System FULL 3BHE044620R6106
UNITROL 1020 MAN Eng. 1CH System FULL+PSS 3BHE044620R6107
Spares Parts Order code

UNITROL 1020-0006 FULL 3BHE030579R0006
UNITROL 1020 SCP door kit 3AUA0000013086 Order Text: OPMP-01-Kit : Mounting
Cabinet Panel ACS
UNITROL 1020 Cable to Panel 3BHE027825R0150 Ethernet Patch Cable, CAT5, RJ45,
connector, shielded,
Length: 150 cm
Color: Gray
7.2 General Technical Data

Excitation Input (AC/DC) Excitation Current Output
AC Nominal voltage (sinusoidal) 0...250 V ac with 3-ph AC or DC supply
AC voltage (max, sinusoidal) 300 V ac Continuous current at 55 °C 20 A
Frequency 40…600 Hz Maximum current for 10 sec 38 A
DC nominal voltage 0...300 V dc with 1-ph AC
Max. DC voltage 420 V dc Continuous current at 55 °C 15 A
Max. peak voltage (non-sinusoidal) 420V peak Maximum current for 10 sec 38 A
Auxiliary Power Supply Input (AC/DC) Machine Voltage Measurement

1-ph AC or DC Nominal voltage 24…240 V Nominal voltage 3 x 110 V ac
Max power consumption 40 W
Network Voltage Measurement
Mechanical Nominal voltage 1 x 110 V ac
Dimension (in mm) 680/425/155
Weight approx. 15 kg Machine Current Measurement
Nominal current 1 to 5 A ac
7.3 Environmental data of the complete AVR plate

Permission ambient Temperature Cable specification
Storage temperature maximum 0°...55 °C Halogen free according IEC 60754-1
Recommended storage temperature 25 °C
Operating temperature -25...55 °C
Maximum heat sink temperature 90 °C

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7.4 Conditions to be in line with UL 508A

ABB confirms that the components and wiring are according to UL 508A.
Remark:
Final compliance with UL 508A can only be committed by the system integrator, who will
install the system. The technical data defined above must be in line with the final applica-
tion.
UL 508A defines maximum ambient temperature for operation to 40°C. In case this level
is exceeded, the system is not compliant with the standard UL 508A.
7.4.1 Disconnecting means for power supply

Disconnecting means for power supply MUST be provided by the system integrator for
following inputs:
 Field flashing input (X 1, 18, 19)
 Voltage measurement inputs UGEN1 (X1, 11, 12, 13) / UNET (X1, 14, 15)
 Control supply voltage UAUX1 (X1, 16, 17)
Machine current transformer (X1, 9, 10) and compounding CT (X1, 1, 2, 3), must not be
disconnected during operation. The system integrator must take care to apply a secure
disconnection option including short circuit of open CT wirings.
7.4.2 Wiring ratings

Wiring ratings are defined in the schematics, document reference 3BHS581347 E20
Class1 (Power cables) and Class 2 (IO cables) are marked on the schematics
Reference is given by cable marking showing the reference number in the schematics.
7.4.3 Terminal ratings

Terminal ratings are defined in the schematics, document reference 3BHS581347 E20
7.4.4 Cable duct specification

All cable ducts are compliant with UL94-V0.

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8 Labels
All systems are equipped with type labels including all needed information to track back the manufactur-
ing of the system.
8.1 Label definition with reference to status

Line 1: Product identification by order code and status
Line 2: Manufacturer
Line 3: Order number of ABB Turgi to manufacturer
Line 4 Serial number by manufacturer
Line 5: Date of routine test at manufacturer site and initials of tester
Product: 3BHE044620R6106/ -
Manufacturer IECO, Helsinki FI
Order no.: 429-2872218
Serial no. 1310012
Date: 4.3.13 SV
8.2 UL 508A specific label
UL 508A specific information

Maximum nominal input voltage: 250V ac or 300V dc
Maximum excitation current 20A dc
Terminal ratings are defined in schematics
Disconnect means for any power inputs are defined in schematics

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9 Revision History
Rev. Page (P) Description Date

ind. Chapt.(C) Dept./Init.
- All Initial Version 30.09.16 /RM
A All Documentation update according to UL 508A 12.12.16 /RM
B All new Input signals Voltage Increase, Voltage Decrease 03.10.17 /SG
and update of various description
C All Additional X1-29 terminals for easier wiring of external 15.01.19 /SG
signals

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AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13

ABB ref. 1637HH101-111
8.
Test Reports
ABB
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AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13

ABB ref. 1637HH101-111
Contents
Test Reports
Generator Test Reports
ABB
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TEST REPORT
Test report for synchronous machines
Customer ABB Automation Products GmbH

Order reference 502572198-100
Project 5304532 Phnom Penh 200 MW, Cambodia
Machine AMG 1600UU12 DSER

Work nr: 1637HH101
Serial nr 4675335
Date 10/15/2019
Approved on the behalf of manufacturer
Yong-ZhiYong Huang
ABB Electrical Machines Ltd.

Visiting Address Postal Address Telefax(Group)
No.1211, Hongyin Rd. No.1211, Hongyin Rd. +86 21 3821 6855
Nanhui District, Shanghai Nanhui District, Shanghai Telefax(Test floor)
P.R. China +86 21 3821 6866
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TEST REPORT
Customer Machine Page
ABB Automation Products GmbH AMG 1600UU12 DSER 2
Order reference Work nr: Serial nr Revision
502572198-100 1637HH101 4675335 A
Project Approved Report rev:
5304532 Phnom Penh 200 MW, Cambodia Yong-ZhiYong Huang A
RATINGS
Standards IEC 60034-1 Classification society None
Insulation class F Mounting IM 7201
Temperature class B Protection class IP 23
Ambient temp. max 43 °C Duty S1
Usage Conn Sn/Pn[kVA] Un [V] In [A] p.f. f [Hz] Um [V] Im [A] Direction n [rpm]
Generator Y 23152 15000 891 0.80 50.0 116 10.6 <== 500
Table of contents / Test Program
1) Visual inspection
2) Air gap measurement and bearing clearance
3) Resistance measurement of windings and elements
4) Insulation resistances before tests
5) First running
6) Direction of rotation, checking of phase sequence
7) No-load point
8) Short-circuit point
9) No-load and short circuit curve, U1 = f(Im) and I1 = f(Im)
10) No-load and short circuit curve, U1 = f(Ir) and I1 = f(Ir)
11) Losses and efficiency
12) Overspeed test
13) Vibration measurement after overspeed
14) High voltage test
15) Insulation resistances after tests
16) Measurement of pump motors
17) Checking of oil flow
18) Checking of CT’s and PT’s connections
19) Tests with regulator
457/616
TEST REPORT
502572198-100 1637HH101 4675335 A
Version Notes
A OK.

Airgap Bearing clearance Axial play
Min [mm] Max [mm] [mm] [mm]
Machine 10.0 10.5 D 0.41 4.90
Exciter 2.5 2.7 N.D 0.41
458/616
TEST REPORT
502572198-100 1637HH101 4675335 A

Resistances of windings
T = 20 °C
Armature windings Ruv [ohm] Ruw [ohm] Rvw [ohm]
Stator 0.06805 0.06807 0.06807
Rotor 0.20054
Exciter
Stator 8.42212
Rotor 0.00376 0.00376 0.00377
Resistances of detectors and space heaters
T = 23.0 °C
Terminal box Terminals Position R [ohm] Detector
B3B 1R1 - 1R2 Stator winding U 108.8 P-t100
B3B 2R1 - 2R2 Stator winding V 108.8 P-t100
B3B 3R1 - 3R2 Stator winding W 109.1 P-t100
B3A 30R1 - 30R2 D-end bearing 109.3 P-t100
B3A 40R1 - 40R2 N.D-end bearing 109.3 P-t100
B3A 1HE1 - 1HE2 Space heater 205.1
T = 23 °C
Winding R [Mohm] U [V] t1 [s]
Stator 2670 5000 60
Rotor 1870 1000 60
Exciter 2460 1000 60
Auxiliaries
Space heater 4150 500 60

Temperature detectors
Stator 3570 500 60
Bearing 2680 500 60
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TEST REPORT
502572198-100 1637HH101 4675335 A
5) First running
Notes OK.

Result U-V-W | L3-L2-L1 | <<< (CCW)
7) No-load point
n [rpm] T [°C] U1 [V] Im [A] Ir [A]
500 29.8 15022 2.85 185.2
Voltage balances
Stator Uuv [V] Uuw [V] Uvw [V]
1 15024 15021 15020
460/616
TEST REPORT
502572198-100 1637HH101 4675335 A
n [rpm] T [°C] I1 [A] Im [A] Ir [A]
500 39.2 895.5 5.24 326.3
Current balances
Stator Iu [A] Iv [A] Iw [A]
1 900 892 895
Ratings 1.6
U1 =15000 V
I1 = 891 A
n = 500 rpm
1.4
No-load curve
T = 29.8 °C
n = 500 rpm
Im [A] U1 [p.u.] 1.2
9.85 1.35
4.86 1.20
3.56 1.10
3.13 1.05 1.0
2.85 1.00
U1 [p.u.], I1 [p.u]
2.57 0.95
2.32 0.90
1.63 0.70 0.8
1.35 0.60
1.06 0.50
0.77 0.40
0.6
0.63 0.35
0.50 0.30
0.36 0.25
0.01 0.10
0.4
Short-circuit curve
T = 39.2 °C
n = 500 rpm
0.2
Im [A] I1 [p.u.]
8.25 1.50
5.80 1.11
5.24 1.01 0.0
3.83 0.75 0 1 2 3 4 5 6 7 8 9 10 11
2.44 0.50 Im [A]
1.03 0.25
U1 I1
0.01 0.09
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TEST REPORT
502572198-100 1637HH101 4675335 A
10) No-load and short circuit curve, U1 = f(Ir) and I1 = f(Ir)

Ratings
1.6
U1 =15000 V
I1 = 891 A
n = 500 rpm
1.4
No-load curve
T = 29.8 °C
n = 500 rpm
Ir [A] U1 [p.u.] 1.2
586.2 1.35
308.6 1.20
229.5 1.10
203.0 1.05 1.0
185.2 1.00
U1 [p.u.], I1 [p.u]
169.2 0.95
154.2 0.90
112.5 0.70 0.8
95.1 0.60
77.6 0.50
60.3 0.40
52.0 0.35 0.6
43.7 0.30
35.4 0.25
11.9 0.10
0.4
Short-circuit curve
T = 39.2 °C
n = 500 rpm
0.2
Ir [A] I1 [p.u.]
490.7 1.50
359.1 1.11
326.3 1.01 0.0
242.6 0.75 0 60 120 180 240 300 360 420 480 540 600 660
159.4 0.50 Ir [A]
74.8 0.25
U1 I1
12.1 0.09
Parameters
Xd (u) = 1.99 pu Xd (s) = 1.80 pu
Xp (s) = 0.26 pu u = unsaturated
Kc (s) = 0.56 s = saturated
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TEST REPORT
502572198-100 1637HH101 4675335 A

Ratings
Connection Y 99.0
Sn = 23152 kVA
Un = 15000 V 98.5
In = 891 A
98.0
Efficiency [%]
fn = 50.00 Hz
Reference temperature, T = 95 °C 97.5
Power factor 0.80
97.0
96.5
96.0
20 30 40 50 60 70 80 90 100 110 120
Load [%]
Losses [kW] 110 % 100 % 75 % 50 % 25 %

Friction losses 46.4 46.4 46.4 46.4 46.4
Iron losses 92.7 92.7 92.7 92.7 92.7
Load losses 176.9 147.8 83.7 37.4 8.5
Excitation losses 93.9 79.4 51.0 31.2 17.8
Total losses 409.9 366.3 273.8 207.7 165.4
Output power 20373.8 18521.6 13891.2 9260.8 4630.4
Input power 20783.6 18887.9 14165.0 9468.5 4795.8
Efficiency 98.03 98.06 98.07 97.81 96.55
Ir[A]: 589.4 541.7 433.5 338.2 254.8
463/616
TEST REPORT
502572198-100 1637HH101 4675335 A

Ratings
Connection Y 99.0
Sn = 23152 kVA
Un = 15000 V 98.5
In = 891 A
98.0
Efficiency [%]
fn = 50.00 Hz
Reference temperature, T = 95 °C 97.5
Power factor 1.00
97.0
96.5
96.0
20 30 40 50 60 70 80 90 100 110 120
Load [%]
Losses [kW] 110 % 100 % 75 % 50 % 25 %

Friction losses 46.4 46.4 46.4 46.4 46.4
Iron losses 92.7 92.7 92.7 92.7 92.7
Load losses 176.9 147.8 83.7 37.4 8.5
Excitation losses 48.9 42.1 27.9 17.9 11.8
Total losses 364.8 329.0 250.7 194.3 159.3
Output power 25467.2 23152.0 17364.0 11576.0 5788.0
Input power 25832.0 23481.0 17614.7 11770.3 5947.3
Efficiency 98.59 98.60 98.58 98.35 97.32
Ir[A]: 424.2 393.2 319.7 254.9 206.4
12) Overspeed test

n = 600 rpm t = 120 s
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TEST REPORT
502572198-100 1637HH101 4675335 A

Bearing position U [V] I [A] n [rpm] Horizontal Vertical Axial Unit
D-END 14941 No-load 500 0.71 0.28 0.37 mm/s, rms
D-END 14941 No-load 500 14.90 8.06 9.98 µm, rms
D-END 14941 No-load 500 0.10 0.12 0.16 m/s², rms
ND-END 14941 No-load 500 0.24 0.18 0.26 mm/s, rms
ND-END 14941 No-load 500 5.94 6.97 8.46 µm, rms
ND-END 14941 No-load 500 0.09 0.23 0.24 m/s², rms
465/616
TEST REPORT
502572198-100 1637HH101 4675335 A

Winding U [V] t [s] f [Hz]
Stator 33000 60 50
Rotor 2000 60 50
Exciter 2400 60 50
Auxiliaries

Stator 1500 60 50
Bearing 500 60 50
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TEST REPORT
502572198-100 1637HH101 4675335 A

T = 29.5°C
Winding R [Mohm] U [V] t [s]
Stator 3270 5000 60
Rotor 8500 1000 60
Exciter 18500 1000 60
Auxiliaries

Stator 50000 500 60
Bearing 50000 500 60
467/616
TEST REPORT
502572198-100 1637HH101 4675335 A

Version A
Measurements
Position P [kW] U [V] Iu [A] Iv [A] Iw[A] f [Hz]
15MP 0.74 380 2.0 2.0 2.0 50
25MP 0.70 380 1.8 1.8 1.8 50
Ratings
Un [V] In [A] Pn [kW] fn [Hz]
380 2.3 0.75 50.0
Notes Jack up pressure:
D-end: 70bar
N-end: 60bar

flow [l/min] p [bar] T [◦C] Viscosity
22.0 2.4 24.8 32
Polarities of voltage transformers checked and found ok.

Polarities of current transformers checked and found ok.
468/616
TEST REPORT
502572198-100 1637HH101 4675335 A
19) Tests with regulator

Version A
Position Main 1
Manufacturer ABB
Type Unitrol 1020
Drawing nr 3BHS581347E20
Sustained short-circuit test

I1, max = 2881 A
Im, max = 20.4 A
n, min = 482 rpm
ECL-10(Pos nr) = 18 Terminals
4-5 5-6 6-7 7-8 9 - 10 10 - 11 11 - 12 12 - 13
open closed closed closed open closed closed open
Other settings
Remanence voltage, U = 2866.6 V
Voltage transformer 15000/165/110
Auxliary voltage, Uaux = 165.0 V
Pulse Width of UM 11.9 %
Direction of Permanent Magnet Ok
469/616
;-----------------------------------------
; ABB Switzerland Ltd
; CMT 1000 v6.311
; Ident: 3BHE030579R0007
; UN1020 Parameter File
; Saved: 15.10.2019, 13:58
; AVR Serial Number: 00001191/2119
; Control SW Version: 6.315
; MCU SW Version: 6.315
;-----------------------------------------
[SYSTEM DATA]
Ie Nominal = 10.6A
Potential Transformer = Three_Phase
UM Nominal = 15.000kV
UM Primary = 15.000kV
UM Secondary = 110.0V
UNet Nominal = 15.00kV
UNet Primary = 15.00kV
UNet Secondary = 110.0V
IM2 Nominal = 891A
IM2 Primary = 1000A
IM2Secondary = 1.000A
CT Phase = 0
Ie No Load = 38.0%
Kceiling = 8.05V/V
Xq = 0.95
f Nominal = 50.00Hz
Single Phase Machine = FALSE
[FIELD FLASHING]
Off Level = 0.0%
[SOFTSTART]
Starting Level = 20.0%
Hold Time = 2.0s
Ramp Time = 8.0s
Frequency Start Threshold = 30.0Hz
Line Charging Starting Level = 20.0%
Line Charging Hold Time = 20.0s
Line Charging Ramp Time = 80.0s
[V/Hz LIMITER]
fKnee = 45.0Hz
Slope = 90.0%
Fdrop = 0.0Hz
MeasDelay = 1000ms
Udrop = 10.0%
Hold Time = 10.0s
Recovery Time = 10.0s
[IeMin LIMITER]
Minimum = 0.0%
Active = FALSE
[IeMax LIMITER]
Maximum = 160.0%
Maximum Hold Time = 10.0s
Delayed = 120.0%
Delayed Hold Time = 60.0s
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Continuous = 105.0%
Active = TRUE
[PQ LIMITER]
Minimum Q (P @ 0%) = -40.0%
Minimum Q (P @ 25%) = -35.0%
Minimum Q (P @ 50%) = -30.0%
Minimum Q (P @ 75%) = -25.0%
Minimum Q (P @ 100%) = -20.0%
Voltage Dependency = TRUE
Active = TRUE
[UM LIMITER]
Minimum = 90.0%
Maximum = 110.0%
Minimum Active = TRUE
Maximum Active = TRUE
UMLim FRT Hold = TRUE
[BOOST]
Threshold = 70.0%
Hold Time = 9.0s
Hysteresis = 15.0%
Delayed OFF = 0.0s
Block Boosting in case of PT Alarm = FALSE
Boost on Grid only = FALSE
[FRT]
Power Threshold = 25.0%
Low Level = 40.0%
High Level = 55.0%
[AUTO SETPOINT]
Initial = 100.0%
Minimum = 90.0%
Maximum = 110.0%
Ramp Rate = 0.30%/s
Disable CB Check = FALSE
PF and VAR Initial SP Enabled = FALSE
Reset SP to Initial SP = FALSE
Loose grid go to initial SP = FALSE
[PF SETPOINT]
Initial = 1.0000
Minimum = -0.9000
Maximum = 0.8000
Ramp Rate = 0.0050/s
[Var SETPOINT]
Initial = 0.0%
Minimum = -20.0%
Maximum = 60.0%
Ramp Rate = 1.00%/s
[MANUAL SETPOINT]
Initial = 0.0%
Minimum = 0.0%
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Maximum = 150.0%
Ramp Rate = 1.67%/s
[OPEN LOOP SETPOINT]

Initial = 0.0%
Minimum = 0.0%
Maximum = 100.0%
Ramp Rate = 1.00%/s
[VDC]
Primary Net ID = 1
Secondary Net ID 1 = 2
Ramp Up Time = 10.0s
Segment Count = 0
Baud Rate = 59.9k
Error on 485 forces Auto = FALSE
Calc Ref from AVRs in VDC mode only = FALSE
VDC Breaker error action = FALSE
Common Section Breakers = FALSE
[DIGITAL I/O 1]
Input = None
Polarity_IN = Normal
Output = Open_FCB_Command
Polarity_OUT = Normal
Direction = Out
[DIGITAL I/O 2]
Input = None
Output = Close_FCB_Command
Direction = Out
[DIGITAL I/O 3]
Input = None
Output = Supervision_Trip
Polarity_OUT = Inverted
Direction = Out
[DIGITAL I/O 4]
Input = External_Alarm
Output = None
Direction = In
[DIGITAL I/O 5]
Input = None
Output = Close_CB_Command
Direction = Out
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[DIGITAL I/O 6]
Input = None
Output = Boost
Direction = Out
[DIGITAL I/O 7]
Input = None
Output = Voltage_Relay
Direction = Out
[DIGITAL I/O 8]
Input = Excitation_ON
Output = None
Direction = In
[DIGITAL INPUT 9]
Input = Gen_CB_Closed
[DIGITAL INPUT 10]

Input = Sync_Dead_Bus_Enable
[DIGITAL INPUT 11]

Input = FCB_closed_Status
[DIGITAL INPUT 12]

Input = EmergencyExcitationOff
[DIGITAL INPUT 13 from +AI]

Input = None
[DIGITAL INPUT 14 from -AI]

Input = None

Input = None

Input = None

473/616
Input = Increase

Input = Decrease
[ANALOG INPUT]
UM Aux Minimum = 0.0%
UM Aux Maximum = 0.0%
PSS Ext Maximum = 25.0%
[ANALOG INPUT 1]
Input = None
Uin 0% = 0.0V
Uin 100% = 10.0V
[ANALOG INPUT 2]
Input = None
Uin 0% = 0.0V
Uin 100% = 10.0V
[ANALOG INPUT 3]
Input = Din17&18
Uin 0% = 2.0V
Uin 100% = 4.0V
[ANALOG OUTPUT]
Output1 = None
Output2 = Fbias
Uout1 0% = 0.0V
Uout1 100% = 10.0V
Uout2 0% = -10.0V
Uout2 100% = 10.0V
Ie 0% = 0.0%
Ie 100% = 300.0%
Fbias 0% = -3.0Hz
Fbias 100% = 3.0Hz
Slip 100% = 10.0Hz
Active Power 0% = -200.0%
Active Power 100% = 200.0%
Ue Field Voltage 100% = 450.0V
Upwr DC Link Voltage 100% = 450.0V
UM relative 0% = 0.0%
UM relative 100% = 200.0%
VAR relative 100% = 200.0%
[TUNE AUTO]
Proportional Gain (Vp) = 29.4
Derivation Time (Tb) = 0.20s
Integration Time (Ta) = 2.06s
Droop (Kq) = 3.0%
Droop (Kq2) = 0.0%
Select Kq2 when parallel to grid = FALSE
Droop On Prel = FALSE
Derivation Gain (Kb) = 3
No Load Power Voltage = 0.0V
Kceil Freq. Dependency = FALSE
474/616
Kceil Freq. Dependency 2 = FALSE

Max. PWM at Boost = FALSE
Uf @ Ie100% = 100%
Uf @ Ie200% = 200%
Uf @ Ie300% = 300%
Uf @ Ie400% = 400%
UfMax = 200%
UfLimGain = 0
HoldExcON = FALSE
UmFilterBS = FALSE
UmFilterLP = FALSE
UnSym. Anti Windup = FALSE
Compounding AVR = FALSE
Switch OFF Loss of Exc Delay = FALSE
Manual SP direct to HIR = FALSE
VeLimiter_en = FALSE
VeLimPWM max = 100.0%
VeLimFreq_dep = FALSE
FreqMin = 0.00Hz
HIR enable = FALSE
HIRLim enable = FALSE
HIR_KCR = 3.0
HIR_Klim = 3.0
HIRVlim = 300.0%
HIR_KCR_T1 = 0.10sec
HIR_KCR_T2 = 0.03sec
HIR_Freq_dep = FALSE
Umerr_Threshold = 5.0%
PosErrCorr_en = FALSE
NegErrCorr_en = FALSE
CTPhaseCalibration = 0.00deg
[TUNE PF/Var/PQ LIMITER]

Indirect PF/Var enable = TRUE
Ramp Rate Indirect = 0.30%/s
Deadband of Q regulator = 2.0%
On delay = 5.0s
[TUNE MANUAL/Ie LIMITER]

[COMMUNICATION]
AVR ID = 1
Channel Identification = Main
TCP IP = 172.16.0.105
SubNet = 255.255.0.0
Gateway = 172.16.0.1
Control Password = 65535
[SYNCHRONIZATION]
UNetOffset = 0.0%
AnglOffset = 0.0deg
Min Slip = 0.00Hz
Max Slip = -0.40Hz
MaxDeltaU = 5.00%
Max Delta Angle = 7deg
Tot CB Close Time = 90ms
475/616
[DIODE MONITORING]
f Exc Nominal = 142Hz
Tconst Exc = 350ms
Active = TRUE
Alarm Level = 5.0%
Alarm Delay = 10.0s
Trip Level = 20.0%
Trip Delay = 0.3s
[PSS]
PSS_SELECT = FALSE
External_PSS = FALSE
TW1 = 5.0s
TW2 = 5.0s
TW3 = 5.0s
TW4 = 0.0s
KS1 = 15.0pu
KS2 = 0.60pu
KS3 = 1.00pu
T1 = 0.10s
T3 = 0.18s
T10 = 0.26s
T12 = 0.00s
T2 = 0.02s
T4 = 0.02s
T11 = 0.02s
T13 = 0.00s
T7 = 5.00s
T8 = 0.00s
T9 = 0.10s
M = 5
N = 1
PSS max = 10.0%
PSS min = -10.0%
VST max = 20.0%
P min = 25.0%
PSS Frequency Gradient = OFF
Frequency XX = 0.00pu
Freq. LeadLag TF1 = 1.00sec
Freq. LeadLag TF2 = 1.00sec
Freq. and P Filter = OFF
Damping Frequency = 6.25Hz
Comp. Gain = 0.0
[IM Limiter]
IMlim_Active = FALSE
IMlim_K = 1.00
IMlim_Im_th = 100.0%
[TEMP INFLUENCE]
IMlim_T1 = 50.0癈
IMlim_Im_th2 = 75.0%
IMlim_T2 = 60.0癈
IMlim_Im_th3 = 50.0%
IMlim_T3 = 70.0癈
IMlim_Im_th4 = 0.0%
IMlim_T4 = 80.0癈
IElim_T1 = 50.0癈
IElim_Ie_th2 = 75.0%
IElim_T2 = 60.0癈
IElim_Ie_th3 = 50.0%
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IElim_T3 = 70.0癈
IElim_Ie_th4 = 0.0%
IElim_T4 = 80.0癈
[MODBUS]
MB Slave ID = 247
MB_Protocol = 0
MB_Bitrate = 7
MB_ChrFrame = 0
MB_KeepAliveTime = 2s
MB_KeepAliveAction = 0
MB_Enable = FALSE
MB_Delay = 10ms
[DOUBLE CHANNEL]
Switchover Start Hold Time = 0.0s
SWO Hold Time Always = FALSE
CAN Enable = TRUE
Alarm 1 Enable = FALSE
Alarm 2 Enable = FALSE
Trip Enable = TRUE
Switchover block at Backup Alarm = FALSE
Switchover block at Backup Trip = TRUE
Alarm(DO) at Standby = TRUE
Trip(DO) at Standby = TRUE
Alarm(DO) Toggling = FALSE
Force Manual at Alarm 1 = FALSE
Force Manual at Alarm 2 = FALSE
Force Excitation Off at Trip = FALSE
Disable ExcOff when GCB active = TRUE
UM Over Voltage Level = 150.0%
UM Over Voltage Hysteresis = 10.0%
UM Over Voltage Detection Time = 1.000s
UM Under Voltage Level = 50.0%
UM Under Voltage Hysteresis = 10.0%
UM Under Voltage Detection Time = 1.000s
Ie Over Current Level = 200.0%
Ie Over Current Hysteresis = 10.0%
Ie Over Current Detection Time = 0.500s
Ue Over Voltage Level = 400.0V
Ue Over Voltage Hysteresis = 40.0V
Ue Over Voltage Detection Time = 1.000s
Upwr Over Voltage Level = 400.0V
Upwr Over Voltage Hysteresis = 40.0V
Upwr Over Voltage Detection Time = 1.000s
Reverse Power Level = -5.0%
Reverse Power Detection Time = 0.500s
Alarm 1 at loss of Remote Control = FALSE
Alarm 1 at Partial loss of UM = FALSE
Alarm 1 at loss of UM = FALSE
Alarm 1 at loss of CT = FALSE
Alarm 1 at loss of UM phase 1 = FALSE
Alarm 1 at loss of Unet = TRUE
Alarm 1 at loss of IM = TRUE
Alarm 1 at loss of control = FALSE
Alarm 1 at loss of excitation = FALSE
Alarm 1 at Temperature 1 = TRUE
Alarm 1 at Temperature 2 = FALSE
Alarm 1 at External Alarm = FALSE
Alarm 1 at 485 Error = FALSE
Alarm 1 at VDC Ring Error = FALSE
477/616
Alarm 1 at Internal Power Fail = FALSE

Alarm 1 at Digital Output Fail = TRUE
Alarm 1 at CAN Monitor = FALSE
Alarm 1 at Monitor Alarm 1 = TRUE
Alarm 1 at Monitor Alarm 2 = FALSE
Monitor Alarm 1 at FCB Alarm = TRUE
Monitor Alarm 1 at Diode Alarm = TRUE
Monitor Alarm 1 at Diode Trip = FALSE
Monitor Alarm 1 at UM Over Voltage = FALSE
Monitor Alarm 1 at UM Under Voltage = FALSE
Monitor Alarm 1 at Ie Over Current = FALSE
Monitor Alarm 1 at Ue Over Voltage = FALSE
Monitor Alarm 1 at Upwr Over Voltage = FALSE
Monitor Alarm 1 at External Alarm = FALSE
Monitor Alarm 1 at Emergency Exc. OFF = FALSE
Monitor Alarm 1 at Reverse Power = FALSE
Monitor Alarm 1 at GCB Alarm = TRUE
Monitor Alarm 1 at AVR output SC = TRUE
Monitor Alarm 1 at Limiter Monitor 1 = FALSE
Alarm 2 at loss of Remote Control = TRUE
Alarm 2 at Partial loss of UM = FALSE
Alarm 2 at loss of UM = FALSE
Alarm 2 at loss of CT = FALSE
Alarm 2 at loss of Unet = FALSE
Alarm 2 at loss of IM = FALSE
Alarm 2 at loss of control = FALSE
Alarm 2 at loss of excitation = FALSE
Alarm 2 at External Alarm = FALSE
Alarm 2 at 485 Error = FALSE
Alarm 2 at VDC Ring Error = FALSE
Alarm 2 at Internal Power Fail = FALSE
Alarm 2 at Digital Output Fail = FALSE
Alarm 2 at CAN Monitor = FALSE
Monitor Alarm 2 at FCB Alarm = FALSE
Monitor Alarm 2 at Diode Alarm = FALSE
Monitor Alarm 2 at Diode Trip = FALSE
Monitor Alarm 2 at Emergency Exc. OFF = FALSE
Monitor Alarm 2 at GCB Alarm = FALSE
Monitor Alarm 2 at AVR output SC = FALSE
Trip at loss of Remote Control = FALSE
Trip at Partial loss of UM = TRUE
Trip at loss of UM = TRUE
Trip at loss of CT = FALSE
Trip at loss of UM phase 1 = TRUE
478/616
Trip at loss of Unet = FALSE

Trip at loss of IM = FALSE
Trip at loss of control = TRUE
Trip at loss of excitation = TRUE
Trip at temperature 1 = FALSE
Trip at Temperature 2 = TRUE
Trip at External Alarm = TRUE
Trip at 485 Error = FALSE
Trip at VDC Ring Error = FALSE
Trip at Internal Power Fail = TRUE
Trip at Digital Output Fail = FALSE
Trip at CAN Monitor = FALSE
Trip at Monitor Alarm 1 = FALSE
Trip at Monitor Alarm 2 = FALSE
Trip at Monitor Alarm 3 = TRUE
Monitor Alarm 3 at FCB Alarm = FALSE
Monitor Alarm 3 at Diode Alarm = FALSE
Monitor Alarm 3 at Diode Trip = TRUE
Monitor Alarm 3 at Emergency Exc. OFF = TRUE
Monitor Alarm 3 at GCB Alarm = FALSE
Monitor Alarm 3 at AVR output SC = FALSE
[LIMITER MONITOR]
Min Ie Limiter 1 = FALSE
Min UM Limiter 1 = FALSE
Min Iq Limiter 1 = FALSE
Max Ie Limiter 1 = FALSE
Max UM Limiter 1 = FALSE
Max IM Limiter 1 = FALSE
V/Hz Limiter 1 = FALSE
Min SP Reached Limiter 1 = FALSE
Max SP Reached Limiter 1 = FALSE
Min Ie Limiter 2 = FALSE
Min UM Limiter 2 = FALSE
Min Iq Limiter 2 = FALSE
Max Ie Limiter 2 = FALSE
Max UM Limiter 2 = FALSE
Max IM Limiter 2 = FALSE
V/Hz Limiter 2 = FALSE
Min SP Reached Limiter 2 = FALSE
Max SP Reached Limiter 2 = FALSE
[TIME]
SNTP IP = 169.254.162.91
SNTP Enabled = FALSE
Time Offset = 01:00
[DATA LOGGER]
Sample Rate = 10ms
Pre Trigger = 50.0%/bit
Trigger Event 1 = 200
479/616

Ext Signal 8 = 379
Ext Signal 9 = 375
Ext Signal 10 = 352
Ext Signal 11 = 397
Ext Signal 12 = 602
[MODBUS CHANNELS]
MB TCP Channel 0 = 350
480/616

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TEST REPORT
502572198-100 1637HH101 4675335 A
End of report
Test bay TA3 (CNEMS test floor, test bench no. 3)
Author Yong
Printed: 10/19/2019
Number of pages 27 Yong-ZhiYong Huang
2.2/7
482/616
TEST REPORT


Work nr: 1637HH102
Serial nr 4675336
Date 10/16/2019
Yong-ZhiYong Huang

P.R. China +86 21 3821 6866
483/616
TEST REPORT
502572198-200 1637HH102 4675336 A
RATINGS
Generator Y 23152 15000 891 0.80 50.0 116 10.6 <== 500
5) First running
7) No-load point
10) Overspeed test
484/616
TEST REPORT
502572198-200 1637HH102 4675336 A
Version Notes
A OK.

Machine 10.0 10.9 D 0.41 4.90
Exciter 2.6 2.7 N.D 0.41
485/616
TEST REPORT
502572198-200 1637HH102 4675336 A

T = 20 °C
Stator 0.06800 0.06802 0.06802
Rotor 0.20033
Exciter
Stator 8.37971
Rotor 0.00376 0.00376 0.00376
T = 23.7 °C
T = 23.7 °C
Stator 2820 5000 60
Rotor 2160 1000 60
Exciter 5300 1000 60
Auxiliaries

Stator 6300 500 60
Bearing 5900 500 60
486/616
TEST REPORT
502572198-200 1637HH102 4675336 A
5) First running
Notes OK.

7) No-load point
n [rpm] T [°C] U1 [V] Im [A]
500 27.8 15000 2.74
Voltage balances
1 15003 15000 14999
487/616
TEST REPORT
502572198-200 1637HH102 4675336 A
n [rpm] T [°C] I1 [A] Im [A]
500 33.9 891.4 5.10
Current balances
1 893 893 889
Ratings 1.6
U1 =15000 V
I1 = 891 A
n = 500 rpm
1.4
No-load curve
T = 27.8 °C
n = 500 rpm
Im [A] U1 [p.u.] 1.2
9.67 1.35
4.76 1.20
3.46 1.10
3.06 1.05 1.0
2.74 1.00
U1 [p.u.], I1 [p.u]
2.49 0.95
2.28 0.90
1.60 0.70 0.8
1.28 0.59
1.04 0.50
0.76 0.40
0.6
0.61 0.34
0.49 0.30
0.34 0.24
0.01 0.10
0.4
Short-circuit curve
T = 33.9 °C
n = 500 rpm
0.2
Im [A] I1 [p.u.]
8.20 1.50
5.64 1.10
5.10 1.00 0.0
3.71 0.75 0 1 2 3 4 5 6 7 8 9 10 11
2.35 0.50 Im [A]
1.03 0.25
U1 I1
0.01 0.07
488/616
TEST REPORT
502572198-200 1637HH102 4675336 A
10) Overspeed test

n = 600 rpm t = 120 s

489/616
TEST REPORT
502572198-200 1637HH102 4675336 A

Stator 33000 60 50
Rotor 2000 60 50
Exciter 2400 60 50
Auxiliaries

Stator 1500 60 50
Bearing 500 60 50
490/616
TEST REPORT
502572198-200 1637HH102 4675336 A

T = 26.9°C
Stator 3660 5000 60
Rotor 3880 1000 60
Exciter 16000 1000 60
Auxiliaries

Stator 30000 500 60
Bearing 30000 500 60

Version A
Measurements
15MP 0.72 384 1.9 1.9 1.9 50
25MP 0.70 384 1.8 1.8 1.8 50

380 2.3 0.75 50.0
D-end: 70 bar
N-end: 60 bar

21.0 2.8 24.6 32

491/616
TEST REPORT
502572198-200 1637HH102 4675336 A
End of report
Author Yong
Printed: 10/19/2019
2.2/7
492/616
TEST REPORT


Work nr: 1637HH103
Serial nr 4675705
Date 10/17/2019
Yong-ZhiYong Huang

P.R. China +86 21 3821 6866
493/616
TEST REPORT
502572198-300 1637HH103 4675705 A
RATINGS
Generator Y 23152 15000 891 0.80 50.0 116 10.6 <== 500
5) First running
7) No-load point
10) Overspeed test
494/616
TEST REPORT
502572198-300 1637HH103 4675705 A
Version Notes
A OK.

Machine 10.0 10.7 D 0.41 5.00
Exciter 2.8 2.9 N.D 0.41
495/616
TEST REPORT
502572198-300 1637HH103 4675705 A

T = 20 °C
Stator 0.06811 0.06813 0.06814
Rotor 0.20129
Exciter
Stator 8.37302
Rotor 0.00375 0.00374 0.00376
T = 20.7 °C
T = 20.7 °C
Stator 2880 5000 60
Rotor 2140 1000 60
Exciter 3600 1000 60
Auxiliaries

Stator 14000 500 60
Bearing 10500 500 60
496/616
TEST REPORT
502572198-300 1637HH103 4675705 A
5) First running
Notes OK.

7) No-load point
n [rpm] T [°C] U1 [V] Im [A]
500 30.2 15011 2.99
Voltage balances
1 15013 15011 15010
497/616
TEST REPORT
502572198-300 1637HH103 4675705 A
n [rpm] T [°C] I1 [A] Im [A]
500 40.5 893.7 5.39
Current balances
1 896 895 891
Ratings 1.6
U1 =15000 V
I1 = 891 A
n = 500 rpm
1.4
No-load curve
T = 30.2 °C
n = 500 rpm
Im [A] U1 [p.u.] 1.2
9.79 1.35
4.99 1.20
3.74 1.10
3.31 1.05 1.0
2.99 1.00
U1 [p.u.], I1 [p.u]
2.73 0.95
2.49 0.90
1.80 0.70 0.8
1.48 0.60
1.22 0.50
0.94 0.40
0.6
0.78 0.35
0.65 0.30
0.52 0.25
0.01 0.06
0.4
Short-circuit curve
T = 40.5 °C
n = 500 rpm
0.2
Im [A] I1 [p.u.]
8.42 1.50
5.93 1.10
5.39 1.00 0.0
3.97 0.75 0 1 2 3 4 5 6 7 8 9 10 11
2.59 0.50 Im [A]
1.21 0.25
U1 I1
0.01 0.05
498/616
TEST REPORT
502572198-300 1637HH103 4675705 A
10) Overspeed test

n = 600 rpm t = 120 s

499/616
TEST REPORT
502572198-300 1637HH103 4675705 A

Stator 33000 60 50
Rotor 2000 60 50
Exciter 2400 60 50
Auxiliaries

Stator 1500 60 50
Bearing 500 60 50
500/616
TEST REPORT
502572198-300 1637HH103 4675705 A

T = 30.5°C
Stator 3470 5000 60
Rotor 3030 1000 60
Exciter 5000 1000 60
Auxiliaries

Stator 15000 500 60
Bearing 12000 500 60

Version A
Measurements
15MP 0.72 385 1.9 1.9 1.9 50
25MP 0.70 385 1.9 1.8 1.9 50

380 2.3 0.75 50.0
D-end: 70 bar
N-end: 60 bar

21.5 2.4 24.4 32

501/616
TEST REPORT
502572198-300 1637HH103 4675705 A
End of report
Author Yong
Printed: 10/19/2019
2.2/7
502/616
TEST REPORT


Work nr: 1637HH104
Serial nr 4675706
Date 10/31/2019
Yong-ZhiYong Huang

P.R. China +86 21 3821 6866
503/616
TEST REPORT
502572198-400 1637HH104 4675706
RATINGS
Generator Y 23152 15000 891 0.80 50.0 116 10.6 <== 500
5) First running
7) No-load point
10) Overspeed test
504/616
TEST REPORT
502572198-400 1637HH104 4675706
Version Notes
A OK.

Machine 9.9 10.9 D 0.40 5.00
Exciter 2.7 2.9 N.D 0.41
505/616
TEST REPORT
502572198-400 1637HH104 4675706

T = 20 °C
Stator 0.06812 0.06813 0.06814
Rotor 0.19863
Exciter
Stator 8.40981
Rotor 0.00375 0.00376 0.00375
T = 20.7 °C
B3B 30R1 - 30R2 D-end bearing 108.2 P-t100
B3B 40R1 - 40R2 N.D-end bearing 108.1 P-t100
T = 20.7 °C
Stator 3610 5000 60
Rotor 2800 1000 60
Exciter 6800 1000 60
Auxiliaries

Stator 15000 500 60
Bearing 1920 500 60
506/616
TEST REPORT
502572198-400 1637HH104 4675706
5) First running
Notes OK.

7) No-load point
n [rpm] T [°C] U1 [V] Im [A]
500 29.3 15030 2.81
Voltage balances
1 15032 15029 15029
507/616
TEST REPORT
502572198-400 1637HH104 4675706
n [rpm] T [°C] I1 [A] Im [A]
500 32.1 891.0 5.07
Current balances
1 893 892 888
Ratings 1.6
U1 =15000 V
I1 = 891 A
n = 500 rpm
1.4
No-load curve
T = 29.3 °C
n = 500 rpm
Im [A] U1 [p.u.] 1.2
9.38 1.35
4.73 1.20
3.57 1.10
3.11 1.05 1.0
2.81 1.00
U1 [p.u.], I1 [p.u]
2.55 0.95
2.34 0.90
1.66 0.70 0.8
1.35 0.60
1.07 0.50
0.81 0.40
0.6
0.68 0.35
0.54 0.30
0.40 0.25
0.01 0.09
0.4
Short-circuit curve
T = 32.1 °C
n = 500 rpm
0.2
Im [A] I1 [p.u.]
7.97 1.50
5.63 1.10
5.07 1.00 0.0
3.73 0.75 0 1 2 3 4 5 6 7 8 9 10 11
2.40 0.50 Im [A]
1.08 0.25
U1 I1
0.01 0.06
508/616
TEST REPORT
502572198-400 1637HH104 4675706
10) Overspeed test

n = 600 rpm t = 120 s

509/616
TEST REPORT
502572198-400 1637HH104 4675706

Stator 33000 60 50
Rotor 2000 60 50
Exciter 2400 60 50
Auxiliaries

Stator 1500 60 50
Bearing 500 60 50
510/616
TEST REPORT
502572198-400 1637HH104 4675706

T = 28.4°C
Stator 3470 5000 60
Rotor 2040 1000 60
Exciter 7800 1000 60
Auxiliaries

Stator 20000 500 60
Bearing 4350 500 60
511/616
TEST REPORT
502572198-400 1637HH104 4675706

Version A
Measurements
15MP 0.72 385 1.9 1.9 1.9 50
25MP 0.71 385 1.8 1.8 1.8 50
Ratings
380 2.3 0.75 50.0
D-end: 70 bar
N-end: 60 bar

21.0 2.4 18.8 32

512/616
TEST REPORT
502572198-400 1637HH104 4675706
End of report
Author Yong
Printed: 11/11/2019
2.2/7
513/616
TEST REPORT


Work nr: 1637HH105
Serial nr 4675707
Date 10/29/2019
Yong-ZhiYong Huang

P.R. China +86 21 3821 6866
514/616
TEST REPORT
502572198-500 1637HH105 4675707
RATINGS
Generator Y 23152 15000 891 0.80 50.0 116 10.6 <== 500
5) First running
7) No-load point
10) Overspeed test
515/616
TEST REPORT
502572198-500 1637HH105 4675707
Version Notes
A OK.

Machine 9.8 10.7 D 0.41 5.00
Exciter 2.6 2.8 N.D 0.39
516/616
TEST REPORT
502572198-500 1637HH105 4675707

T = 20 °C
Stator 0.06783 0.06786 0.06785
Rotor 0.20088
Exciter
Stator 8.37063
Rotor 0.00376 0.00376 0.00376
T = 19.0 °C
T = 19 °C
Stator 3220 5000 60
Rotor 2550 1000 60
Exciter 4650 1000 60
Auxiliaries

Stator 17500 500 60
Bearing 14000 500 60
517/616
TEST REPORT
502572198-500 1637HH105 4675707
5) First running
Notes OK.

7) No-load point
n [rpm] T [°C] U1 [V] Im [A]
500 29.4 15028 2.91
Voltage balances
1 15030 15028 15027
518/616
TEST REPORT
502572198-500 1637HH105 4675707
n [rpm] T [°C] I1 [A] Im [A]
500 31.5 892.0 5.19
Current balances
1 894 893 889
Ratings 1.6
U1 =15000 V
I1 = 891 A
n = 500 rpm
1.4
No-load curve
T = 29.4 °C
n = 500 rpm
Im [A] U1 [p.u.] 1.2
9.59 1.35
4.86 1.20
3.60 1.10
3.21 1.05 1.0
2.91 1.00
U1 [p.u.], I1 [p.u]
2.67 0.95
2.43 0.90
1.75 0.70 0.8
1.47 0.60
1.18 0.50
0.91 0.40
0.6
0.77 0.35
0.64 0.30
0.52 0.25
0.01 0.05
0.4
Short-circuit curve
T = 31.5 °C
n = 500 rpm
0.2
Im [A] I1 [p.u.]
8.00 1.49
5.72 1.10
5.18 1.00 0.0
3.83 0.75 0 1 2 3 4 5 6 7 8 9 10 11
2.51 0.50 Im [A]
1.17 0.25
U1 I1
0.01 0.05
519/616
TEST REPORT
502572198-500 1637HH105 4675707
10) Overspeed test

n = 600 rpm t = 120 s

520/616
TEST REPORT
502572198-500 1637HH105 4675707

Stator 33000 60 50
Rotor 2000 60 50
Exciter 2400 60 50
Auxiliaries

Stator 1500 60 50
Bearing 500 60 50
521/616
TEST REPORT
502572198-500 1637HH105 4675707

T = 27.2°C
Stator 3370 5000 60
Rotor 3300 1000 60
Exciter 62000 1000 60
Auxiliaries

Stator 30000 500 60
Bearing 22000 500 60
522/616
TEST REPORT
502572198-500 1637HH105 4675707

Version A
Measurements
15MP 0.72 385 1.9 1.9 1.9 50
25MP 0.71 385 1.9 1.9 1.9 50
Ratings
380 2.3 0.75 50.0
D-end: 70 bar
N-end: 55 bar

22.0 2.4 21.0 32

523/616
TEST REPORT
502572198-500 1637HH105 4675707
End of report
Author Yong
Printed: 11/1/2019
2.2/7
524/616
TEST REPORT


Work nr: 1637HH106
Serial nr 4675708
Date 10/30/2019
Yong-ZhiYong Huang

P.R. China +86 21 3821 6866
525/616
TEST REPORT
502572198-600 1637HH106 4675708 A
RATINGS
Generator Y 23152 15000 891 0.80 50.0 116 10.6 <== 500
5) First running
7) No-load point
10) Overspeed test
526/616
TEST REPORT
502572198-600 1637HH106 4675708 A
Version Notes
A OK.

Machine 9.9 10.8 D 0.39 5.00
Exciter 2.6 2.7 N.D 0.40
527/616
TEST REPORT
502572198-600 1637HH106 4675708 A

T = 20 °C
Stator 0.06784 0.06786 0.06782
Rotor 0.20051
Exciter
Stator 8.36247
Rotor 0.00379 0.00377 0.00377
T = 18.9 °C
T = 18.9 °C
Stator 3920 5000 60
Rotor 4500 1000 60
Exciter 8500 1000 60
Auxiliaries

Stator 45000 500 60
Bearing 9200 500 60
528/616
TEST REPORT
502572198-600 1637HH106 4675708 A
5) First running
Notes OK.

7) No-load point
n [rpm] T [°C] U1 [V] Im [A]
500 28.8 15010 2.80
Voltage balances
1 15012 15009 15008
529/616
TEST REPORT
502572198-600 1637HH106 4675708 A
n [rpm] T [°C] I1 [A] Im [A]
500 36.5 892.4 5.09
Current balances
1 894 894 889
Ratings 1.6
U1 =15000 V
I1 = 891 A
n = 500 rpm
1.4
No-load curve
T = 28.8 °C
n = 500 rpm
Im [A] U1 [p.u.] 1.2
9.37 1.35
4.76 1.20
3.52 1.10
3.12 1.05 1.0
2.80 1.00
U1 [p.u.], I1 [p.u]
2.56 0.95
2.36 0.90
1.69 0.70 0.8
1.42 0.60
1.14 0.50
0.88 0.40
0.6
0.75 0.35
0.62 0.30
0.47 0.25
0.01 0.06
0.4
Short-circuit curve
T = 36.5 °C
n = 500 rpm
0.2
Im [A] I1 [p.u.]
8.02 1.51
5.61 1.10
5.09 1.00 0.0
3.75 0.75 0 1 2 3 4 5 6 7 8 9 10 11
2.41 0.49 Im [A]
1.13 0.25
U1 I1
0.01 0.05
530/616
TEST REPORT
502572198-600 1637HH106 4675708 A
10) Overspeed test

n = 600 rpm t = 120 s

531/616
TEST REPORT
502572198-600 1637HH106 4675708 A

Stator 33000 60 50
Rotor 2000 60 50
Exciter 2400 60 50
Auxiliaries

Stator 1500 60 50
Bearing 500 60 50
532/616
TEST REPORT
502572198-600 1637HH106 4675708 A

T = 27.7°C
Stator 3290 5000 60
Rotor 4800 1000 60
Exciter 5600 1000 60
Auxiliaries

Stator 40000 500 60
Bearing 7800 500 60
533/616
TEST REPORT
502572198-600 1637HH106 4675708 A

Version A
Measurements
15MP 0.68 385 1.8 1.8 1.8 50
25MP 0.70 385 1.8 1.8 1.8 50
Ratings
380 2.3 0.75 50.0
D-end: 70 bar
N-end: 55 bar

21.0 2.4 22.2 32

534/616
TEST REPORT
502572198-600 1637HH106 4675708 A
End of report
Author Yong
Printed: 11/5/2019
2.2/7
535/616
TEST REPORT


Work nr: 1637HH107
Serial nr 4675709
Date 11/4/2019
Yong-ZhiYong Huang

P.R. China +86 21 3821 6866
536/616
TEST REPORT
502572198-700 1637HH107 4675709 A
RATINGS
Generator Y 23152 15000 891 0.80 50.0 116 10.6 <== 500
5) First running
7) No-load point
10) Overspeed test
537/616
TEST REPORT
502572198-700 1637HH107 4675709 A
Version Notes
A OK.

Machine 10.1 10.6 D 0.41 5.00
Exciter 2.6 2.7 N.D 0.41
538/616
TEST REPORT
502572198-700 1637HH107 4675709 A

T = 20 °C
Stator 0.06772 0.06772 0.06773
Rotor 0.20043
Exciter
Stator 8.35861
Rotor 0.00376 0.00377 0.00377
T = 19.6 °C
T = 19.6 °C
Stator 2860 5000 60
Rotor 1600 1000 60
Exciter 3660 1000 60
Auxiliaries

Stator 13500 500 60
Bearing 14000 500 60
539/616
TEST REPORT
502572198-700 1637HH107 4675709 A
5) First running
Notes OK.

7) No-load point
n [rpm] T [°C] U1 [V] Im [A]
500 24.8 15002 2.82
Voltage balances
1 15004 15001 15000
540/616
TEST REPORT
502572198-700 1637HH107 4675709 A
n [rpm] T [°C] I1 [A] Im [A]
500 38.2 891.9 5.13
Current balances
1 894 893 889
Ratings 1.6
U1 =15000 V
I1 = 891 A
n = 500 rpm
1.4
No-load curve
T = 24.8 °C
n = 500 rpm
Im [A] U1 [p.u.] 1.2
9.34 1.35
4.75 1.20
3.50 1.10
3.09 1.05 1.0
2.82 1.00
U1 [p.u.], I1 [p.u]
2.57 0.95
2.36 0.90
1.70 0.70 0.8
1.42 0.60
1.15 0.50
0.88 0.40
0.6
0.76 0.35
0.62 0.30
0.48 0.25
0.01 0.06
0.4
Short-circuit curve
T = 38.5 °C
n = 500 rpm
0.2
Im [A] I1 [p.u.]
8.06 1.50
5.68 1.10
5.13 1.00 0.0
3.77 0.75 0 1 2 3 4 5 6 7 8 9 10 11
2.46 0.50 Im [A]
1.15 0.25
U1 I1
0.01 0.05
541/616
TEST REPORT
502572198-700 1637HH107 4675709 A
10) Overspeed test

n = 600 rpm t = 120 s

542/616
TEST REPORT
502572198-700 1637HH107 4675709 A

Stator 33000 60 50
Rotor 2000 60 50
Exciter 2400 60 50
Auxiliaries

Stator 1500 60 50
Bearing 500 60 50
543/616
TEST REPORT
502572198-700 1637HH107 4675709 A

T = 26.9°C
Stator 3390 5000 60
Rotor 2090 1000 60
Exciter 7700 1000 60
Auxiliaries

Stator 28000 500 60
Bearing 24000 500 60
544/616
TEST REPORT
502572198-700 1637HH107 4675709 A

Version A
Measurements
15MP 0.69 385 1.8 1.8 1.8 50
25MP 0.72 385 1.9 1.9 1.9 50
Ratings
380 2.3 0.75 50.0
D-end: 70 bar
N-end: 55 bar

21.0 2.4 20.3 32

545/616
TEST REPORT
502572198-700 1637HH107 4675709 A
End of report
Author Yong
Printed: 11/8/2019
2.2/7
546/616
TEST REPORT


Work nr: 1637HH108
Serial nr 4675710
Date 11/25/2019
Yong-ZhiYong Huang

P.R. China +86 21 3821 6866
547/616
TEST REPORT
502572198-800 1637HH108 4675710 A
RATINGS
Generator Y 23152 15000 891 0.80 50.0 116 10.6 <== 500
5) First running
7) No-load point
10) Overspeed test
548/616
TEST REPORT
502572198-800 1637HH108 4675710 A
Version Notes
A OK.

Machine 9.9 11.1 D 0.42 5.00
Exciter 2.7 2.9 N.D 0.42
549/616
TEST REPORT
502572198-800 1637HH108 4675710 A

T = 20 °C
Stator 0.06779 0.06779 0.06779
Rotor 0.20046
Exciter
Stator 8.36953
Rotor 0.00373 0.00374 0.00374
T = 16.8 °C
T = 16.8 °C
Stator 1720 5000 60
Rotor 269 1000 60
Exciter 3700 1000 60
Auxiliaries

Stator 7400 500 60
Bearing 8600 500 60
550/616
TEST REPORT
502572198-800 1637HH108 4675710 A
5) First running
Notes OK.

7) No-load point
n [rpm] T [°C] U1 [V] Im [A]
500 23.6 15010 2.74
Voltage balances
1 15013 15009 15008
551/616
TEST REPORT
502572198-800 1637HH108 4675710 A
n [rpm] T [°C] I1 [A] Im [A]
500 28.8 890.6 5.13
Current balances
1 892 892 887
Ratings 1.6
U1 =15000 V
I1 = 891 A
n = 500 rpm
1.4
No-load curve
T = 23.6 °C
n = 500 rpm
Im [A] U1 [p.u.] 1.2
9.72 1.35
4.77 1.20
3.48 1.10
3.06 1.05 1.0
2.74 1.00
U1 [p.u.], I1 [p.u]
2.50 0.95
2.27 0.90
1.60 0.70 0.8
1.30 0.60
1.02 0.50
0.78 0.40
0.6
0.62 0.35
0.49 0.30
0.37 0.25
0.01 0.11
0.4
Short-circuit curve
T = 28.8 °C
n = 500 rpm
0.2
Im [A] I1 [p.u.]
8.25 1.50
5.70 1.10
5.13 1.00 0.0
3.73 0.75 0 1 2 3 4 5 6 7 8 9 10 11
2.41 0.50 Im [A]
1.04 0.25
U1 I1
0.01 0.07
552/616
TEST REPORT
502572198-800 1637HH108 4675710 A
10) Overspeed test

n = 600 rpm t = 120 s

553/616
TEST REPORT
502572198-800 1637HH108 4675710 A

Stator 33000 60 50
Rotor 2000 60 50
Exciter 2400 60 50
Auxiliaries

Stator 1500 60 50
Bearing 500 60 50
554/616
TEST REPORT
502572198-800 1637HH108 4675710 A

T = 23.8°C
Stator 3400 5000 60
Rotor 6500 1000 60
Exciter 27000 1000 60
Auxiliaries

Stator 45000 500 60
Bearing 30000 500 60
555/616
TEST REPORT
502572198-800 1637HH108 4675710 A

Version A
Measurements
15MP 0.70 385 1.9 1.9 1.9 50
25MP 0.71 385 1.9 1.9 1.9 50
Ratings
380 2.3 0.75 50.0
D-end: 70 bar
N-end: 55 bar

22.0 2.4 21.7 32

556/616
TEST REPORT
502572198-800 1637HH108 4675710 A
End of report
Author Yong
Printed: 12/4/2019
2.2/7
557/616
TEST REPORT


Work nr: 1637HH109
Serial nr 4675711
Date 11/28/2019
Yong-ZhiYong Huang

P.R. China +86 21 3821 6866
558/616
TEST REPORT
502572198-900 1637HH109 4675711 A
RATINGS
Generator Y 23152 15000 891 0.80 50.0 116 10.6 <== 500
5) First running
7) No-load point
10) Overspeed test
559/616
TEST REPORT
502572198-900 1637HH109 4675711 A
Version Notes
A OK.

Machine 9.9 10.8 D 0.38 5.00
Exciter 2.6 2.8 N.D 0.41
560/616
TEST REPORT
502572198-900 1637HH109 4675711 A

T = 20 °C
Stator 0.06773 0.06776 0.06775
Rotor 0.20065
Exciter
Stator 8.31375
Rotor 0.00373 0.00373 0.00373
T = 15.1 °C
T = 15.1 °C
Stator 3330 5000 60
Rotor 2190 1000 60
Exciter 5300 1000 60
Auxiliaries

Stator 60000 500 60
Bearing 45000 500 60
561/616
TEST REPORT
502572198-900 1637HH109 4675711 A
5) First running
Notes OK.

7) No-load point
n [rpm] T [°C] U1 [V] Im [A]
500 20.8 15016 2.83
Voltage balances
1 15019 15015 15013
562/616
TEST REPORT
502572198-900 1637HH109 4675711 A
n [rpm] T [°C] I1 [A] Im [A]
500 25.9 890.6 5.10
Current balances
1 892 892 888
Ratings 1.6
U1 =15000 V
I1 = 891 A
n = 500 rpm
1.4
No-load curve
T = 20.8 °C
n = 500 rpm
Im [A] U1 [p.u.] 1.2
9.32 1.35
4.76 1.20
3.54 1.10
3.13 1.05 1.0
2.83 1.00
U1 [p.u.], I1 [p.u]
2.57 0.95
2.37 0.90
1.70 0.70 0.8
1.41 0.60
1.15 0.50
0.88 0.40
0.6
0.73 0.35
0.62 0.30
0.50 0.25
0.01 0.06
0.4
Short-circuit curve
T = 25.9 °C
n = 500 rpm
0.2
Im [A] I1 [p.u.]
8.02 1.50
5.64 1.10
5.10 1.00 0.0
3.75 0.75 0 1 2 3 4 5 6 7 8 9 10 11
2.46 0.50 Im [A]
1.14 0.25
U1 I1
0.01 0.04
563/616
TEST REPORT
502572198-900 1637HH109 4675711 A
10) Overspeed test

n = 600 rpm t = 120 s

564/616
TEST REPORT
502572198-900 1637HH109 4675711 A

Stator 33000 60 50
Rotor 2000 60 50
Exciter 2400 60 50
Auxiliaries

Stator 1500 60 50
Bearing 500 60 50
565/616
TEST REPORT
502572198-900 1637HH109 4675711 A

T = 22.8°C
Stator 3490 5000 60
Rotor 4200 1000 60
Exciter 35000 1000 60
Auxiliaries

Stator 100000 500 60
Bearing 100000 500 60
566/616
TEST REPORT
502572198-900 1637HH109 4675711 A

Version A
Measurements
15MP 0.69 384 1.8 1.8 1.8 50
25MP 0.70 384 1.9 1.9 1.9 50
Ratings
380 2.3 0.75 50.0
D-end: 60 bar
N-end: 60 bar

23.0 2.4 15.9 32

567/616
TEST REPORT
502572198-900 1637HH109 4675711 A
End of report
Author Yong
Printed: 12/4/2019
2.2/7
568/616
TEST REPORT


Work nr: 1637HH110
Serial nr 4675712
Date 11/29/2019
Yong-ZhiYong Huang

P.R. China +86 21 3821 6866
569/616
TEST REPORT
502572198-1000 1637HH110 4675712 A
RATINGS
Generator Y 23152 15000 891 0.80 50.0 116 10.6 <== 500
5) First running
7) No-load point
10) Overspeed test
570/616
TEST REPORT
502572198-1000 1637HH110 4675712 A
Version Notes
A OK.

Machine 9.8 10.5 D 0.40 5.00
Exciter 2.5 2.7 N.D 0.41
571/616
TEST REPORT
502572198-1000 1637HH110 4675712 A

T = 20 °C
Stator 0.06764 0.06767 0.06766
Rotor 0.20035
Exciter
Stator 8.33429
Rotor 0.00370 0.00370 0.00370
T = 14.6 °C
T = 14.6 °C
Stator 3360 5000 60
Rotor 4550 1000 60
Exciter 13500 1000 60
Auxiliaries

Stator 35000 500 60
Bearing 36000 500 60
572/616
TEST REPORT
502572198-1000 1637HH110 4675712 A
5) First running
Notes OK.

7) No-load point
n [rpm] T [°C] U1 [V] Im [A]
500 21.6 15003 2.67
Voltage balances
1 15006 15002 15000
573/616
TEST REPORT
502572198-1000 1637HH110 4675712 A
n [rpm] T [°C] I1 [A] Im [A]
500 30.3 891.8 5.03
Current balances
1 893 893 889
Ratings 1.6
U1 =15000 V
I1 = 891 A
n = 500 rpm
1.4
No-load curve
T = 21.6 °C
n = 500 rpm
Im [A] U1 [p.u.] 1.2
9.21 1.35
4.58 1.20
3.37 1.10
3.00 1.05 1.0
2.67 1.00
U1 [p.u.], I1 [p.u]
2.41 0.95
2.21 0.90
1.54 0.70 0.8
1.28 0.60
1.01 0.50
0.75 0.40
0.6
0.63 0.35
0.48 0.30
0.36 0.25
0.01 0.10
0.4
Short-circuit curve
T = 30.3 °C
n = 500 rpm
0.2
Im [A] I1 [p.u.]
8.05 1.50
5.55 1.10
5.03 1.00 0.0
3.63 0.75 0 1 2 3 4 5 6 7 8 9 10 11
2.31 0.50 Im [A]
1.01 0.25
U1 I1
0.01 0.06
574/616
TEST REPORT
502572198-1000 1637HH110 4675712 A
10) Overspeed test

n = 600 rpm t = 120 s

575/616
TEST REPORT
502572198-1000 1637HH110 4675712 A

Stator 33000 60 50
Rotor 2000 60 50
Exciter 2400 60 50
Auxiliaries

Stator 1500 60 50
Bearing 500 60 50
576/616
TEST REPORT
502572198-1000 1637HH110 4675712 A

T = 22.3°C
Stator 3300 5000 60
Rotor 5800 1000 60
Exciter 19500 1000 60
Auxiliaries

Stator 50000 500 60
Bearing 60000 500 60
577/616
TEST REPORT
502572198-1000 1637HH110 4675712 A

Version A
Measurements
15MP 0.70 384 1.9 1.8 1.9 50
25MP 0.71 384 1.9 1.9 1.9 50
Ratings
380 2.3 0.75 50.0
D-end: 70 bar
N-end: 60 bar

22.0 2.4 17.7 32

578/616
TEST REPORT
502572198-1000 1637HH110 4675712 A
End of report
Author Yong
Printed: 12/4/2019
2.2/7
579/616
TEST REPORT


Work nr: 1637HH111
Serial nr 4675713
Date 1/12/2020
Yong-ZhiYong Huang

P.R. China +86 21 3821 6866
580/616
TEST REPORT
502572198-1100 1637HH111 4675713 A
RATINGS
Generator Y 23152 15000 891 0.80 50.0 116 10.6 <== 500
5) First running
7) No-load point
10) Overspeed test
581/616
TEST REPORT
502572198-1100 1637HH111 4675713 A
Version Notes
A OK.

Machine 10.0 11.0 D 0.41 4.90
Exciter 2.7 2.8 N.D 0.42
582/616
TEST REPORT
502572198-1100 1637HH111 4675713 A

T = 20 °C
Stator 0.06766 0.06760 0.06767
Rotor 0.20076
Exciter
Stator 8.43120
Rotor 0.00370 0.00370 0.00369
T = 12.1 °C
T = 12.1 °C
Stator 3700 5000 60
Rotor 2330 1000 60
Exciter 6000 1000 60
Auxiliaries

Stator 21000 500 60
Bearing 16000 500 60
583/616
TEST REPORT
502572198-1100 1637HH111 4675713 A
5) First running
Notes OK.

7) No-load point
n [rpm] T [°C] U1 [V] Im [A]
500 18.9 15028 2.75
Voltage balances
1 15030 15027 15027
584/616
TEST REPORT
502572198-1100 1637HH111 4675713 A
n [rpm] T [°C] I1 [A] Im [A]
500 27.8 890.9 5.09
Current balances
1 892 893 888
Ratings 1.6
U1 =15000 V
I1 = 891 A
n = 500 rpm
1.4
No-load curve
T = 18.9 °C
n = 500 rpm
Im [A] U1 [p.u.] 1.2
9.16 1.35
4.65 1.20
3.44 1.10
3.05 1.05 1.0
2.75 1.00
U1 [p.u.], I1 [p.u]
2.49 0.95
2.28 0.90
1.61 0.70 0.8
1.32 0.60
1.04 0.50
0.77 0.40
0.6
0.64 0.35
0.50 0.30
0.38 0.25
0.01 0.10
0.4
Short-circuit curve
T = 27.8 °C
n = 500 rpm
0.2
Im [A] I1 [p.u.]
8.03 1.50
5.63 1.10
5.09 1.00 0.0
3.74 0.75 0 1 2 3 4 5 6 7 8 9 10 11
2.41 0.50 Im [A]
1.09 0.26
U1 I1
0.01 0.06
585/616
TEST REPORT
502572198-1100 1637HH111 4675713 A
10) Overspeed test

n = 600 rpm t = 120 s

586/616
TEST REPORT
502572198-1100 1637HH111 4675713 A

Stator 33000 60 50
Rotor 2000 60 50
Exciter 2400 60 50
Auxiliaries

Stator 1500 60 50
Bearing 500 60 50
587/616
TEST REPORT
502572198-1100 1637HH111 4675713 A

T = 22.0°C
Stator 3690 5000 60
Rotor 11500 1000 60
Exciter 45000 1000 60
Auxiliaries

Stator 100000 500 60
Bearing 100000 500 60
588/616
TEST REPORT
502572198-1100 1637HH111 4675713 A

Version A
Measurements
15MP 0.70 385 1.9 1.9 1.9 50
25MP 0.71 385 1.9 1.9 1.9 50
Ratings
380 2.3 0.75 50.0
D-end: 70 bar
N-end: 60 bar

22.0 2.4 18.7 32

589/616
TEST REPORT
502572198-1100 1637HH111 4675713 A
End of report
Author Yong
Printed: 1/13/2020
2.2/7
590/616

AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13

ABB ref. 1637HH101-111
9.
Check Lists
ABB
591/616

AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13

ABB ref. 1637HH101-111
Contents
Check Lists
Commissioning Report
Test Record for Winding Maintenance
Recommended Supervision Inspection Program
Pt-100 Failure Inspection Protocol
Check List for Renk Bearings
ABB
592/616

Section 9 - Check Lists
Serial no. 4675335-36, 4675705-13

ABB Ref. 1637HH101-111
November 2019 Project: MAN 5304532 Phnom Penh MW, Cambodia
Project
COMMISSIONING REPORT
Rating Plate Information: 3 ~ Synchronous Machine AMG1 600UU12 DSER
Serial no. 4675335-36, 4675705-13
Manufacturer: ABB Electrical Machines Ltd
Address: 380 TianXing Road
Minhang District
200245 Shanghai
China
Telephone: +86 21 6113 7688
Telefax: +86 21 6113 7788
Customer:
Customer Address:
Contact Person:
Telephone:
Mobile phone:
Fax:
Email:
Commissioning Report - 1
593/616

Serial no. 4675335-36, 4675705-13

ABB Ref. 1637HH101-111
Project
1 Transportation
General:
Arrival date of the machine:
Inspection date and location:
Signature of consignee:
Open box inspection: no yes, done by:
Damages:
Packing list: no yes, missing items:
Machine: no yes, what kind of:
Package: no yes, what kind of:
Accessories: no yes, what kind of:
Spare parts + tools: no yes, what kind of:
Actions Taken in Response to Damages:
Photographed: no yes, date:
Reported to the transportation company: no yes, to whom: date:
Reported to the supplier: no yes, to whom: date:
Reported to the insurance company: no yes, to whom: date:
Method of Transportation:
Railway Airfreight Truck Mail Shipped by M/S ___________ Other:
Comments:
594/616

Serial no. 4675335-36, 4675705-13

ABB Ref. 1637HH101-111
Project
2 Storage
General:
Storage: no yes, begin:_______________end:_____________________
Storage Time Longer than 6 Months: no yes
Person Responsible for Storage:
Storage Place:
indoors outdoors
in packing case protected by a waterproof cover
Daily temperature: min/max._______ - _______ºC Humidity:_______%

Storage Actions:
Transportation package is ventilated: no yes
External heating/fan is used: no yes, type:______________________________________
Machine space heaters are used: no yes, voltage:____________________________________
Bearings are flushed: no yes, oil type:____________________________________
Bearing shells are removed: no yes, date:______________________________________
Shaft end anti-corrosion protection checked: no yes, type:______________________________________
Shaft end anti-corrosion protection renewed: no yes, date:______________________________________
The rotor is turned 10 revolutions every two

months: no yes
There are vibrations in the storage place: no yes, __________mm/s, rms

There are corrosive gases in the air: no yes, what kind of:__________________________________
Brushes are lifted up: no yes
Machine documents are saved and protected
for future use: no yes, location:_____________________________________
Comments:
595/616

Serial no. 4675335-36, 4675705-13

ABB Ref. 1637HH101-111
Project
3 Mechanical Installation
Foundation is checked according to machine
drawing: no yes, drawing number:_____________________________
Possible foundation anchor bolts or sole
plates are mounted according to instructions: no yes
Air gap is measured: D-end N-end Exciter N-end

For pedestal bearings, mark values 1-4, and top top top
for flanged bearings, values A-D
1 ____________ A ____________ 1 1 1
D A D A D A
2 ____________ B ____________ 4 2 4 2 4 2
3 ____________ C ____________ C B C B C B
3 3 3
4 ____________ D ____________
For alignment of the coupling, use either Radial alignment of coupling Angular alignment of coupling
values 1-4 or values A-D top top
1 ____________
1 A 1 A
2 ____________ D D
3 ____________ 4 2 4 2
4 ____________ C B C B
3 3
A ____________
Axial position of the rotor: ET #1:__________mm, ET #2:__________mm
B ____________
C ____________ Axial distance between shaft ends: __________mm

Rotor support distance:
D ____________
______mm ______mm
Crankshaft deflection is checked: no yes
Tapered guide pins are used to lock the
position of the machine after alignment: no yes
Foundations bolts are tightened with torque

wrench: no yes, bolt size:_____________torque:_______________Nm
Bolt lubrication: dry oil, MoS2
Cooling water: no yes, amount: m3/s
Cooling element piping: flexible rigid
Transport locking device is removed: no yes

Rotor rotates without noise or scraping: no yes
596/616

Serial no. 4675335-36, 4675705-13

ABB Ref. 1637HH101-111
Project
4 Lubrication check
4.1 Self lubrication

Bearing oil: Manufacturer:__________________ Type:_________________________
The oil quality is the same as recommended : no yes
Bearing oil is filled up to the indicated level:
Please mark the level in the sight glass circle Sight Glass
on the right
Lubrication rings rotate freely: no yes
4.2 Forced lubrication

Bearing oil: Manufacturer:__________________ Type:_________________________
The oil quality is the same as recommended: no yes
Lubrication rings rotate freely: no yes
Force lubrication oil pressure: ___________kPa
Oil flow: ___________liters/min
Rotation of the pumps checked: no yes
Jack-up pumps checked: no yes, alarm setting:_____kPa, relief valve setting:______kPa

Oil filters checked: no yes
4.3 Grease lubricated bearings:

Grease: Manufacturer:__________________ Type:_________________________
The grease quality is the same as
recommended on the lubrication plate: no yes
The first greasing has been done: Date:_______________ Quantity:________g

Comments:
597/616

Serial no. 4675335-36, 4675705-13

ABB Ref. 1637HH101-111
Project
5 Electrical installation
Network variation: no yes, voltage:______-______V, frequency:_____-______Hz
Space heater operation: no manual automatic, controlled by:_________________
Space heater for slip ring unit: no yes, voltage:_____________V, power:_______________W
5.1 Insulation Resistance Test

Stator winding (1 min.): __________MΩ, tested by________ kV, winding temperature:______ºC
Stator winding (15 / 60 s. or 1 / 10 min.): PI =__________, tested by________ kV, winding temperature:______ºC
Rotor winding (1 min., 500 VDC): __________MΩ, tested by________ kV, winding temperature:______ºC
Exciter stator (1 min., 500 VDC): __________MΩ, tested by________ kV, winding temperature:______ºC
Space heater: __________MΩ (500 VDC)
Temperature detectors: __________MΩ (100 VDC)
N-end bearing insulation: __________MΩ (100 VDC)
5.2 Accessories resistance test

Stator 1 PT 100: __________Ω
Stator 2 PT 100: __________Ω
Stator 3 PT 100: __________Ω
Stator 4 PT 100: __________Ω
Stator 5 PT 100: __________Ω
Stator 6 PT 100: __________Ω
Bearing PT 100 D-end: __________Ω
Bearing PT 100 N-end: __________Ω
Air temperature 1 PT 100: __________Ω
Air temperature 2 PT 100: __________Ω
Space heater: __________Ω
598/616

Serial no. 4675335-36, 4675705-13

ABB Ref. 1637HH101-111
Project
6 Machine protection settings
Overcurrent tripping: _______________A _________________ s
Instant overcurrent tripping: _______________A _________________ s
Overvoltage setting: no yes, setting:
Earth fault setting: no yes, setting:

Reverse power setting: no yes, setting:
Differential protection setting: no yes, setting:
Vibration monitoring: no yes, alarm:__________mm/s, trip:______________mm/s
Temperature monitoring:
- in stator winding no yes, alarm:__________ºC, trip:______________ºC

- in bearing no yes, alarm:__________ºC, trip:______________ºC
- in ______________________________ no yes, alarm:__________ºC, trip:______________ºC
Other protection units: no yes, type:
599/616

Serial no. 4675335-36, 4675705-13

ABB Ref. 1637HH101-111
Project
7 Test Run
7.1 First start (a few seconds only)

Note: Check that possible force lubrication is on!
Direction of rotation (viewed from D-end): CW CCW
Are there abnormal noises? no yes, from:
7.2 Second start (uncoupled, if possible)

Note: Check that possible force lubrication is on!
Are there abnormal noises? no yes, from:
Does the machine vibrate abnormally? no yes, where/how:
Bearing vibration level measured: D-end:__________ mm/s, rms; N-end:_________ mm/s, rms
Running: machine run OK operation stops, why:
Checking schedule and information

Time Bearing temperature Bearing vibration levels Stator Stator winding temperature
D-end N-end D-end N-end Current Power Excit. U V W
mm/s mm/s Factor Current
h:min ºC ºC rms rms A cos φ A ºC ºC ºC
0:00
0:05
0:10
0:15
0:20
Comments:
Observations:
600/616

Serial no. 4675335-36, 4675705-13

ABB Ref. 1637HH101-111
Project
8 Test run (with load)
Checking schedule and information
Time Load Bearing temp. Bearing vibration levels Stator Stator winding temperature
D-end N-end D-end N-end Current Power Excit. U V W
mm/s mm/s Factor Current
h:min % ºC ºC rms rms A cos φ A ºC ºC ºC
0:00
Vibration spectrum attached: no yes

Acceleration time: __________ s.
Cooling air temperature: Inlet: __________ ºC Outlet:__________ ºC
Cooling water temperature: Inlet: __________ ºC Outlet:__________ ºC
Comments:
9 Machine approval
Machine approved for use Date:
Commissioning done by:
Approved by:
601/616

Serial no. 4675335-36, 4675705-13

ABB Ref. 1637HH101-111
Project
Test Record for Winding Maintenance
TEST RECORD Machine type: No:
Annual inspection Use: No:

Inspection every 4 years Voltage/output: V/ kW
Random inspection Running hours: h
Distribution: Date/inspected by: /

1. Seals OK Observations:
2. Fixing air guiding plates etc. OK Observations:
3. Contamination Stator Rotor Commutator Air Cooling Explanations End

windings windings brushgear ducts radiators D/N
Total amount of dirt
Grease, oil
Dry dirt, dust
Dampness, rust
QUANTITY ESTIMATION
0 = clean 1 = slightly dirty 2 = ducts about to plug 3 = ducts are plugged
ESTIMATION BASIS
1 = dropping 2 = loosening 3 = cracking 4 = breaking
5 = dust, caused by vibration 6 = swelling 7 = darkening 8 = embrittlement
9 = water marks 10 = tracking current 11 = hair cracks 12 = risen bars
marks
13 = battered 14 = knocking: doubtful 15 = corrosion 16 = leakages
17 = condensation 18 = loose ribs 19 = abrasion 20 = noise from bearing
21 = other noises 22 = other flaws
-1
602/616

Serial no. 4675335-36, 4675705-13

ABB Ref. 1637HH101-111
Project
4. WINDINGS OK Observations D/N

4.1 AC Stator
Support
Coils
Connecting cables
Core laminations
4.2 Synchronous rotor
Coils, insulations, support
Pole, poleshoe, bolts
Connection ring
4.3 Asynchronous rotor
Ends of squir. cage windings
Key of squir. cage ring
Core laminations
4.4 DC stator
Windings, insulations
Fixing the windings
Connecting leads
4.5 DC rotor
Coils
Bandage
Core laminations
5. FAN
6. COOLING SYSTEM
Visible radiator parts
Inner radiator parts
Flow-switch
-2
603/616

Serial no. 4675335-36, 4675705-13

ABB Ref. 1637HH101-111
Project
7. ELECTRICAL CONNECTIONS
Main connection
Control gear
8. ELECTRICAL TESTS
Insulation resistance to earth R15= MΩ, R60= MΩ
Winding temperature:
Voltage test 1 min. Test voltage:
Operation test of protection Voltage kV, DC voltage AC voltage
-3
604/616

Serial no. 4675335-36, 4675705-13

ABB Ref. 1637HH101-111
Project
Recommended Supervision Inspection Program
Machine type: Serial number:

Point of inspection: Date:
Stator current kA
Excitation current A
Bearing temperature, D-end °C
Bearing temperature, ND-end °C
°C
°C
Winding temperature, 1U °C
Winding temperature, 1V °C
Winding temperature, 1W °C
Winding temperature, 2U °C
Winding temperature, 2V °C
Winding temperature, 2W °C
Cold air temperature, D-end °C
Cold air temperature, ND-end °C
Hot air temperature, D-end °C
Hot air temperature, ND-end °C
-1
605/616

Serial no. 4675335-36, 4675705-13

ABB Ref. 1637HH101-111
Project
Machine type: Serial number:

Point of inspection: Date:
Vrms
Vibration level, D-end / axial [mm/s]
/vertical Vrms
[mm/s]
/ horizontal /transversal Vrms
[mm/s]
Vibration level, ND-end / axial Vrms
[mm/s]
/ vertical Vrms
[mm/s]
/ horizontal /transversal Vrms
[mm/s]
Quantity of coolant m3 / h
Water leakage (YES/NO)
Operation of automatic grease system (YES/NO)
Empty of N- and D-end waste grease box
Oil flow/oil pressure l/min /
bar
Oil leakage (YES/NO)
Fault indication (YES/NO)
Other observations / comments:
-2
606/616

Serial no. 4675335-36, 4675705-13

ABB Ref. 1637HH101-111
Project
Pt-100 Failure Inspection Protocol
This check list helps to provide ABB with sufficient data to determine the cause of Pt-100 sensor damages. Please mark N/A
on points not valid in your case.
1 General
Customer:
Azipod Generator Motor
Type of machine:
Serial number:
Project name or order number:
2 Operational information
Start up date (dd/mm/yyyy):
Application:
Operating hours before failure: h
Output at the time of failure: Power: kW Speed: rpm
Current: A Temperature: °C
Normal operating load: Power: kW Current: A
Normal operating temperatures:
D-end: °C Stator: °C
N-end: °C Rotor: °C
Ambient temperature: °C
Minimum and maximum ambient temperatures: °C °C
Service done before damage:
Disturbances before damage (e.g. high vibration):
-1
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Serial no. 4675335-36, 4675705-13

ABB Ref. 1637HH101-111
Project
3 Additional information
Where the damaged sensors are and how many sensors are damaged:
Stator winding Bearing Hot air Cool air
When the damage was discovered:
Were several sensors damaged at the same time:
Were there other damages in system at the same time:
How the damage was discovered: In monitoring system If otherwise, how:
Where were the sensors checked after damage: In junction box If not, where:
Manufacturer of damaged sensor:

Minco Thermo-Est Some other, who:
Resistance between 3-wire Minco sensor wires, if other sensor, update colors:
red-blue red-white blue-white
4 Current situation
Where is the machine at the moment:
What has been done so far to the machine due to this damage:
Additional comments:
5 Material to be provided to ABB

Photographs of machine:
Temperature trend curves:
Other material:
-2
608/616

Serial no. 4675335-36, 4675705-13

ABB Ref. 1637HH101-111
Project
6 Contact information
Date (dd/mm/yyyy):
Place:
Signature:
Name, title:
Company:
Phone:
Fax:
E-mail:
Thank you very much for your co-operation!
-3
609/616

Oil Leakages in RENK Slide Bearings

A Check List for Horizontal Bearings
In case of oil leakages in the bearing area, this check list may help you to find fail reasons or to set up a
detailed fail report to our service department. Your answers to the necessary questions will help us to find
the reasons for, and solutions to, the problems.
General Information
1.1 Machine Scheme (designation convention and description)

Bearg. Bearg.
MACHINE Type of machine: ___________________

DE NDE
Type of machine: ___________________

coupled to DE
2 Seals 1 1 Seals  2 (Seal position e.g. DE_2 or NDE_1)
(in case of leaking seals, mark the desired check-box)
1.2 Read the following information from the nameplate of the bearing:
Bearing Type: (e.g. EFZLA 14-140) DE _____________ NDE _____________
RENK Ref. N°: (e.g. 446 123) DE _____________ NDE _____________
Oil viscosity: (e.g. ISO VG 46) DE _____________ NDE _____________
1.3. Type of oil applied:  unknown Manufacturer: _________________
Denomination: _________________
1.4 Information on operational conditions:
nominal speed: ________ RPM overspeed: _____________ RPM
RENK Check List for Horizontal Bearings - 1

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1.5 Types of mounted seals:
DE_1: Type ___ DE_2: Type ___ NDE_1: Type ___ NDE_2: Type ___
(add-ons to basic types)
Type “10” Type “20” Type + 1 Type + 2

Floating Labyrinth S. Rigid Labyrinth S. Dust Flinger Bolt-on Baffle
(Type numbers for basic seals with "add-on": Type 11 or 12 respective Type 21 or 22)
2.1 Intensity of oil leakages:
 less than 2 drops per day

 less than 10 drops per day
 more than 10 drops per day
2.2 Location of leakages:
 seals (please answer questions 3 - 25, 30)

 screw connections / pipes (please answer questions 26 - 30)
 split line of bearing housings (please answer questions 3 - 8, 14, 22, 29, 30)
3. Is the oil level correct?  yes  no
4. Does the oil foam heavily? yes  no
5. Is the foam visible  yes  no

in the sight glass?
6. Normal bearing shell temperature?
 unknown ____ °C
7. Oil sump temperature?
 unknown ____ °C

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8. Machine and bearings horizontally aligned?
 yes no, inclination (axline): ____°
 marine application axline: ____° across: ____°
Shaft Seals - Details
9. Where do the leakages at the seal appear?
 between seal and shaft

 between seal and housing
 difficult to recognise
10. Seals gap to shaft - can you measure the gaps at 12, 3, 6, and 9 o'clock positions with a view towards
the bearing? The seal should not be disassembled before.
Please also note the seal’s machine-position.
If not possible, can you measure the shaft diameter at the seal’s seat instead?
 no  yes: please note below
⎯|⎯ ⎯|⎯ (mm)
⎯|⎯ ⎯|⎯ (mm)
11. Did you find gaps in the split line of seals (by means of a feeler / plate gauge)?
(In the case of a Floating Labyrinth Seal: fit the seal with its garter spring - but without the carrier - onto
the shaft)
 no  yes: note gaps below
<⎯|⎯> <⎯|⎯> (mm)
12. Is there any damaged baffle (at seals)?
 yes  no
13. Are the oil drain holes of the seals in the lower half and are they open to the bearing housing?
 yes  no

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14. Has "Curil T" (or other non-hardening sealant) been applied to all joints, split lines of housings, and
seals as well as between housing and seals prior to assembly?
 yes  no
15. If Floating Lab. seal is used, has "Curil T" been applied to the flanks of the seals?
 yes  no
16. Are there deflectors at the shaft between the bearing shell and seal area?
 yes  no
Differences in Air Pressure / Air Streams
17. Are there components outside the bearing, close to the seal area, which might cause a draught (fans,
cooling discs, couplings, flywheels, belt drives)?
 yes  no
Distance in between: ______ mm
18. Is there a difference in air pressure between the inside bearing and the outside (low or high pressure
differences of more than 30 Pa respective 3 mm water column are of interest; please mark low pressure
with minus)?
 no  could not be measured
DE: ____ Pa NDE: ____ Pa
19. Is there low or high pressure in front of the seals (at the machine side of flanged bearings - housings
EF or EM - you can measure in the channels respective connections for air pressure compensation)?
 no  could not be measured
DE_1: ____ Pa DE_2: ____ Pa
NDE_1: ____ Pa NDE_2: ____ Pa
20. If there is a breather mounted at the bearing house, is this device (filter) dry and clean?
 no device device mounted

 yes  no. oil-wet --> or: __
21. In case of pressure differences, do you have any idea of their origin (note it please)?

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External Oil Supply
If there is only a circulation from the oil sump of the bearing direct to the bearing entry (oil circulation pump
at each bearing), please strike out questions 23, 24 and 25.
22. Please note oil throughput + oil pressure + oil temperature at each bearing entry:
 unknown
DE: ____ l/min ____ bar ____ °C
NDE: ____ l/min ____ bar ____ °C
23. Inclination of oil return pipe between bearing and oil tank:
 < 10 deg.  ≥ 10 deg > 15 deg.
24. Nominal diameter of oil return pipe
________ mm
25. If you found high pressure inside the bearing, is it possible that this pressure comes along the oil
return pipe (from the tank; e.g. produced by pressurised air seals of other components in the oil circulation
system)?
 yes  no
Screw Connections and Vibrations
26. Which screw connections are leaking?
 locking screw with plastic seal

 locking screw with copper gasket
 oil sight glass
 connection of oil return pipe - with hexagon nut and lead gasket
27. Are the locking screws tightened according to torques (Nm) given below?
G 1/8: 18 G 1/4: 22 G 3/8: 30

G 1/2: 40 G 3/4: 60 G 1 : ..110
G 1 1/4: 160 G 1 1/2: 230 G 2 : ..320
G 2 1/2: 500
 yes  no

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28. Has the screw connection of the oil return pipe in the bearing house been relieved of the tube weight
by appropriate fixing devices?
 yes  no
29. Are there vibrations in the oil return pipe?
 no  low  strong
30. Did you measure the vibrations of the housings and/or of the shaft?
 no  yes, Veff = _____ mm/s
amplitude Smax = ____ µm
RENK AG, Werk Hannover (Germany)

Dept.: HVA (after sales service)
Fax: +49.511.8601 - 288
e-mail: hva_ha@renk.de

615/616

AMG 1600UU12 DSER
Serial no. 4675335-36, 4675705-13

ABB ref. 1637HH101-111
10.
Additional
Information
ABB
616/616
ABB
ABB Electrical Machines Ltd
380 TianXing Road
Minhang District
200245 Shanghai
CHINA
Telephone +86 21 6113 7688
Telefax +86 21 6113 7788

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User’s Manual Synchronous Machine

Serial no. 4675335-36, 4675705-13

MAN Material Numbers: 11.70123-2073

User’s Manual Synchronous Machine

Serial no. 4675335-36, 4675705-13

Technical Specification ...........3

Mechanical Drawings ..............4

Additional Information ...........10

User’s Manual Synchronous Machine

Serial no. 4675335-36, 4675705-13

Synchronous Machine AMG 1600UU12 DSER

Synchronous Machine AMG 1600UU12 DSER

The following recommendations are for general guidance:

4.1 Symbols and decals

4.2 Electrical hazard

4.3 Moving parts

Synchronous Machine AMG 1600UU12 DSER

4.4 High temperatures

4.5 Electro-Static Devices (ESD)

4.6 Magnetic fields

5. Safety Instructions (High-voltage AC Machines)

5.2 Intended use

Synchronous Machine AMG 1600UU12 DSER

5.3 Transport, storage

5.5 Electrical connection

Synchronous Machine AMG 1600UU12 DSER

5.7 Maintenance and servicing

6. Disposal and recycling instructions

User’s Manual Synchronous Machine

Serial no. 4675335-36, 4675705-13

User’s Manual Synchronous Machine

Serial no. 4675335-36, 4675705-13

Declaration of Incorporation can be found on the

User’s Manual Synchronous Machine

Serial no. 4675335-36, 4675705-13

User’s Manual Synchronous Machine

Serial no. 4675335-36, 4675705-13

Project name: 5304532 Phnom Penh 200 MW, Cambodia

1 PERFORMANCE DATA (Calculated values) 3

ABB Oy / Motors and Generators 3AFP 16377101 en B 1

Revision Change Date Updated by

Document identification Lang. Rev. ind. Sheet

ABB Oy / Motors and Generators 3AFP 16377101 en B 2

1 PERFORMANCE DATA (Calculated values)

ENVIRONMENTAL CONDITIONS (max. values)

TIME CONSTANTS (sec.) AT 75 °C

Document identification Lang. Rev. ind. Sheet

ABB Oy / Motors and Generators 3AFP 16377101 en B 3

TERMINAL CONNECTIONS (Viewed facing drive end)

Exciter field Power to the exciter field:1.22kW

Document identification Lang. Rev. ind. Sheet

ABB Oy / Motors and Generators 3AFP 16377101 en B 4

Document identification Lang. Rev. ind. Sheet

ABB Oy / Motors and Generators 3AFP 16377101 en B 5

2 CONFIGURATION AND SCOPE OF SUPPLY

Document identification Lang. Rev. ind. Sheet

ABB Oy / Motors and Generators 3AFP 16377101 en B 6