ABB AMS 800SF Generator Installation Manual

Installation and Synchronous generator,
maintenance type AMS 800SF

NOTICE
The information in this document is subject to change without notice and should not be construed as a commitment by ABB AB,
Machines. ABB AB, Machines assumes no responsibility for any errors that may appear in this document.
In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any kind arising from the use
of this document, nor shall ABB be liable for incidential or consequential damages arising from the use of any software or
hardware described in this document.
This document and parts thereof must not be reproduced or copied without ABB AB, Machines’s written permission, and the
contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.
©Copyright 2001 ABB. All rights reserved.

Skeleton No. 3BSM005467, Rev. A EN -
Synchronous generator, type AMS
Table of Contents
Chapter 1 - Introduction
1.1 General information.................................................................................................... 4
1.2 Safety .......................................................................................................................... 4
1.3 Site conditions............................................................................................................. 4
1.4 Prerequisites................................................................................................................ 5
1.5 Contraindications ........................................................................................................ 5
1.6 Manual system and related documents ....................................................................... 6
Chapter 2 - Transport, Storage and Preparation for erection

2.1 Transport and unpacking ............................................................................................ 7
2.1.1 Protective measures prior to transport ....................................................... 7
2.1.2 Check upon arrival..................................................................................... 7
2.1.3 Transport anchor points ............................................................................. 8
2.1.4 Transport anchor points ............................................................................. 9
2.1.5 Lifting of crated equipment ..................................................................... 10
2.1.6 Unpacking................................................................................................ 10
2.1.7 Lifting of equipment ................................................................................ 11
2.2 Storage (this generator is prepared for long term storage) ....................................... 13
2.2.1 Short term storage of crated generator..................................................... 13
2.2.2 Long term storage of crated generator..................................................... 14
2.2.3 Short term storage of uncrated generator................................................. 15
2.2.4 Long term storage of uncrated generator................................................. 15
2.3 Preparation for erection ............................................................................................ 16
2.3.1 Check of foundation................................................................................. 16
2.3.2 Vertical and horizontal positioning.......................................................... 17
2.3.3 Removal of the transport locking device ................................................. 19
Chapter 3 - Alignment
3.1 Preparations for generator installation...................................................................... 20
3.2 Rough levelling of generator after erection .............................................................. 21
3.2.1 Rough alignment...................................................................................... 21
3.3 Grouting .................................................................................................................... 21
3.4 Correction for thermal expansion ............................................................................. 22
3.5 Final alignment and inspection ................................................................................. 22
Chapter 4 - Mechanical and electrical installation

4.1 Mechanical installation ............................................................................................. 23
4.1.1 Cooling arrangement................................................................................ 23
Skeleton No. 3BSM005469, Rev. - EN -
4.1.2 Connection of oil pipes ............................................................................ 23

4.1.3 Mounting of main terminal box ............................................................... 24
3BSY 200016-EYZ i
Table of Contents
4.2 Electrical installation ................................................................................................ 24

4.2.1 Connection of control equipment ............................................................ 24
4.2.2 Connection of high voltage cables........................................................... 25
4.2.3 Earth connection ...................................................................................... 25
Chapter 5 - Commissioning
5.1 Check of mechanical installation.............................................................................. 26
5.2 Check of electrical installation ................................................................................. 27
5.3 Electrical checks ....................................................................................................... 28
5.3.1 Start interlocking...................................................................................... 32
5.4 Checks during running of the generator ................................................................... 33
5.4.1 Normal vibration levels ........................................................................... 33
5.4.1.1 Bearing housings ...............................................................33
5.4.1.2 Structural vibrations ..........................................................34
5.4.1.3 Shaft vibrations .................................................................34
5.4.2 Temperature levels................................................................................... 34
5.5 Check list .................................................................................................................. 35
5.5.1 Page 1....................................................................................................... 36
5.5.2 Page 2....................................................................................................... 37
5.5.3 Page 3....................................................................................................... 38
Chapter 6 - Operation
6.1 Start up procedure..................................................................................................... 39
6.2 Continuous supervision............................................................................................. 39
6.3 Shut down procedures............................................................................................... 40
6.4 Alarm during operation............................................................................................. 40
Chapter 7 - Maintenance
7.1 Preventive maintenance ............................................................................................ 43
7.2 Before all maintenance work .................................................................................... 43
7.3 Recommended maintenance program....................................................................... 44
7.3.1 Generator ................................................................................................. 45
7.3.2 Stator........................................................................................................ 46
7.3.3 Stator terminal.......................................................................................... 47
7.3.4 Rotor ........................................................................................................ 48
7.3.5 Bearings ................................................................................................... 50
7.3.6 PMG (Permanent magnetic generator) .................................................... 51
7.3.7 Exciter and Rectifier ............................................................................... 52
7.3.8 Cooling system ........................................................................................ 53

7.3.9 AVR (Automatic Voltage Regulator) and
Generator Protection System ................................................................... 53
3BSY 200016-EYZ ii
Table of Contents
7.3.10 Purge system ............................................................................................ 53

7.4 Main rotor coil turn insulation (voltage drop test).................................................... 53
7.5 Fault finding.............................................................................................................. 54
7.5.1 Diode fault ............................................................................................... 54
7.5.2 Altering the firing voltage........................................................................ 56
7.5.3 Lubrication............................................................................................... 57
7.5.4 High temperature in bearing .................................................................... 59
7.5.4.1 Trouble shooting 1 ............................................................59
7.5.5 High winding and / or air temperature..................................................... 62
7.5.5.1 Trouble shooting ...............................................................62
Chapter 8 - Disposal and Recycling

8.1 General...................................................................................................................... 63
8.2 Dismantling the machine .......................................................................................... 63
8.3 Separation of different types of material .................................................................. 63
8.3.1 Normal carbon steel ................................................................................. 63
8.3.2 Electrical silicon steel non oriented ......................................................... 64
8.3.3 Special high quality steel ......................................................................... 64
8.3.4 Mixed metallic material ........................................................................... 64
8.3.5 Stainless steel........................................................................................... 64
8.3.6 Cast iron................................................................................................... 64
8.3.7 Aluminium ............................................................................................... 65
8.3.8 Copper...................................................................................................... 65
8.4 Waste as land fill....................................................................................................... 66
8.5 Hazardous waste ....................................................................................................... 66
8.6 Final comments......................................................................................................... 66
3BSY 200016-EYZ iii

Chapter 1 Introduction
1.1 General information

• This installation and maintenance manual for the generator is a part of the main
documentation for this project. (refer to Section 1.6).
• This document is a manual for the generator with serial number 8267 772 -8267 773 and
manufacturers order number L000159.
• Actions described in this manual are only to be performed by trained personnel with
previous experience in similar tasks, and authorized by the user.
1.2 Safety
The machine is manufactured and intended for use only as described by this manual.
Modification, alteration, or lack of maintenance as described in the manual, may
adversely affect the safety and efficacy of this machine. The manufacturer is not
responsible for malfunctions that comprise machinesafety as a result of alteration, use of
non ABB replacements parts, neglect or misuse.
Replacements parts may vary from those shown in this manual. Should you have questions on
those parts please contact ABB AB, Machines.
The actual apperarance of the machine may vary from the illustration in this manual.
Should pre-owned ABB equipment be purchased and reconditioned, the equipment should not
be used until testing and analysis demonstrate that the equipment meets the original or upgraded
specifications.
The use of solvents as cleaning agents and the use of lubricants can involve health and/or safety
hazards. The recommended precautions and procedures of the manufacturer should be followed.
1.3 Site conditions

This generator is to be used on a site with conditions according to ABB AB, Machines´s
Technical Specification (included in binder “Users Manual”), clause D “Site conditions” and
nowhere else.
Skeleton No. 3BSM005470, Rev. B EN -
3BSY 200016-EYZ 1-4

1.4 Prerequisites
The operator must:
• be proficient in the application of the machine and electricity.
• be thoroughly trained in the skills and have the knowledge required to operate this
machine.
• be thoroughly familiar with the contents of this manual and other operator´s manuals that
deals with the machine and accessory devices that may be used with this machine.
• be fully qualified and trained in the operation of this machine and able to distinguish
normal from aberrant device behaviour.
• never reset an alarm or trip until the reason for the alarm/trip has been located and
necessary remedy has been made to make a safe restart of the machine.
1.5 Contraindications
The machine is not designed, sold or intended for any use except as indicated above.
Furthermore, it is not intended to be used outside of the machine specifications or limitations.
The machine must be in good working order.
3BSY 200016-EYZ 1-5

1.6 Manual system and related documents
Project: TUNU 11S

Project number: L000159
Serial number 8267 772 -8267 773
Users Manual ABB AB, Machines

for the generator Scope of Supply
General ABB AB, Machines

AMS Synchronous generator
Technical Specification
Drawings for the generator
Circuit Diagrams
Machine part list
Installation & Maintenance manual

Test Reports
Accessories & Instructions
Main terminal box

3BSY 200016-EYZ 1-6

Chapter 2 Transport, Storage and Preparation for erection
2.1 Transport and unpacking
2.1.1 Protective measures prior to transport

• Irrespective of the method of transport or the distance, all generators are provided with an
axial movement locking device on the drive end bearing, to protect the bearings against
damage during transport.
• Machined metal surfaces, such as the shaft extension, are provided 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 for even the longest transport distances.
• For shipping overseas a generator of this size is packed in a strong wooden crate and
should be located under deck. The wooden crate is provided with metal plates for
protection and indications showing where the lifting wires are to be applied.
2.1.2 Check upon arrival

When the transport company delivers a generator to the customer, the responsibility for the
handling passes to the customer or other party. Any transport damage must be reported 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 are to be checked and reported immediately to the
transport company and the supplier.
A generator which is not to be installed immediately upon arrival must not be left without
neither supervision nor without protective precautions. If the storage period is to be 9 months or
more special precautions must be taken.
Skeleton No. 3BSM005471, Rev. D EN -
3BSY 200016-EYZ 2-7

2.1.3 Transport anchor points
CAUTION - Risk of component damage

Components on the generator housing can get damage during transport.
1. Make sure the anchoring is tight so no movement is allowed in either direction.
Anchoring point
Optional anchoring point

It is important to be careful within this area.
Figure 2-1
Anchor points during transport on lorry. Beware of area that is dotted in accordance with Figure
2-1 on page 8.
3BSY 200016-EYZ 2-8

2.1.4 Transport anchor points
CAUTION - Risk of component damage

Components on the generator housing can get damaged during transport.
1. Make sure the anchoring is tight so no movement is allowed in either direction.
Anchor point
Figure 2-2
Anchor points during transport on lorry or by vessel, located on both sides of the crate.
3BSY 200016-EYZ 2-9

2.1.5 Lifting of crated equipment
WARNING - Heavy lift

The crate with equipment is very heavy.
1. Use lifting equipment that is appropriate for the load.
2. Lifting must be performed with great care and using steel cables long enough to assure the
angle requirements shown in Figure 2-3 on page 10. Centre of Gravity is shown on each
crate.
0.86xB
60o
Figure 2-3
2.1.6 Unpacking
Place the generator so that it is out of the way of any other goods handling and on a flat,
vibration-free surface.
Remove top and sides of the wooden crate.
When the crating has been removed a check should be made to see that the generator is not
damaged and that all accessories are included. Tick off the accessories on the packing list which
is enclosed. Report immediately to the supplier if there is any damage, suspected damage or if
accessories are missing.
3BSY 200016-EYZ 2-10

2.1.7 Lifting of equipment
WARNING - Heavy Lift

The generator is very heavy.
1. Use lifting equipment that is appropriate for the load, see “Technical Specification” for
weight.
Lifting must be performed with great care and using steel cables long enough to assure the angle
requirements shown in Figure 2-4 on page 11. (Otherwise there will be risk of damaging the
upper sheet metal housing).
60o
0.86xL
L
Figure 2-4
3BSY 200016-EYZ 2-11

WARNING - Heavy Lift

The cooler top is very heavy.
1. Use lifting equipment that is appropriate for the load, see outline drawing included in the
binder “Users Manual”.
When lifting the cooler top only use lifting lugs according to Figure 2-5 on page 12, the other
lifting lugs are not designed to lift the complete cooling top.
If the cooler top is delivered in separate parts, assemble the parts according to the cooler
supplier’s drawings and manuals included in the binder “Users Manual”.
NOTE: Centre of gravity is moved towards the “fan side”. Compensate by using different
length on the lifting lugs.
Figure 2-5
3BSY 200016-EYZ 2-12


The terminal box is very heavy.
1. Use lifting equipment that is appropriate for the load, see outline drawing included in the
binder “Users Manual”.
.
Figure 2-6 on page 13 shows an example how the main terminal box should be lifted. As an
option a smaller box could be included in the scope of supply, instead of as shown in Figure 2-6
on page 13. Then it will just be supplied with two lifting loops on top.
Not included
Figure 2-6
2.2 Storage (this generator is prepared for long term storage)
2.2.1 Short term storage of crated generator
Storage < 9 month

Measures to be taken by customer or other part.
• The machine should be left in the crate.
• The crate should preferably be stored indoors and shall be placed on a vibration-free, flat
and well-drained surface. If the crate is to be stored outdoors, the crate must be covered
with a tarpaulin on the top extending at least 1 meter out from the crate to avoid direct rain
on the crate.
• The crate should be kept dry, protected from rain and moisture.
Before commissioning the following items should be carried out:
• Visual external inspection of bearings and entering shaft
• Check insulation resistance in accordance with section 5.3
3BSY 200016-EYZ 2-13

2.2.2 Long term storage of crated generator
Storage > 9 month

Long-term storage must be notified before delivery, so that the machine can be prepared and
packed for the actual condition. If an unscheduled long-term storage is needed, please contact
ABB.
The machine should preferably be stored indoors and shall be placed on a vibration-free, flat
and well-drained surface.
1. Remove top and sides of the wooden crate.
2. Open the plastic protection to allow for a good ventilation.
3. The machine should be protected from rain and moisture. If the machine is to be stored
outdoors, it must be covered with a tarpaulin on the top extending at least 1 meter out from
the crate to avoid direct rain on the machine. If the machine is stored in a harsh
environment measures should be taken to protect it against dust and dirt.
4. To avoid condensation in the machine, the heating elements in main machine and exciter
must be connected according to the circuit diagram, included in the binder “Users
Manual”.
5. Check regularly the anti-corrosion coating on NOT painted areas like shaft, flanges etc.
and touch up if necessary.
6. Measures should be taken to ensure that the heaters work properly at all time.
7. Corrosion preventive oil should be filled in the bearings, according to section 3.1 on page
20, once every 12 month. Rotation of the rotor is not required.
8. The axial transport-locking device must always be mounted during transportation of the
machine.
• Visual external inspection of bearings and entering shaft.
• Visual inspection of exciter.
• Visual inspection of rotor and stator windings.
• The corrosion preventive oil in the bearings must be drained before rotation.
• Check insulation resistance in accordance with section 5.3.
3BSY 200016-EYZ 2-14

2.2.3 Short term storage of uncrated generator
Storage < 9 month

1. Open the plastic protection to allow for a good ventilation.
2. The machine should be protected from rain and moisture. If the machine is to be stored
outdoors, it must be covered with a tarpaulin on the top extending at least 1 meter out from
the crate to avoid direct rain on the machine and be placed on at least 100 mm high rigid
supports, as to make sure that no water can enter the machine from below. If the machine is
stored in a harsh environment measures should be taken to protect it against dust and dirt.
3. To avoid condensation in the machine, the heating elements in main machine and exciter
must be connected according to the circuit diagram, included in the binder “Users
Manual”.
4. Check regularly the anti-corrosion coating on NOT painted areas like shaft, flanges etc.
and touch up if necessary.
5. Measures should be taken to ensure that the heaters work properly at all time.
6. The axial transport-locking device must always be mounted during transportation of the
machine
2.2.4 Long term storage of uncrated generator
Storage > 9 month

Long-term storage must be notified before delivery, so that the machine can be prepared and
packed for the actual condition. If an unscheduled long-term storage is needed, please contact
ABB.
Measures to be taken accordance with section 2.2.3 ” Short term storage of machine, <
9 month” and in accordance to below:
• Corrosion preventive oil should be filled in the bearings, according to section 3.1 on page
20, once every 12 month. Rotation of the rotor is not required.

• Visual inspection of exciter.
• Visual inspection of rotor and stator windings.
• The corrosion preventive oil in the bearings must be drained before rotation.
3BSY 200016-EYZ 2-15

2.3 Preparation for erection

The structural design of the foundation is not included in ABB´s undertaking, the customer or a
third party is therefore responsible for this. Furthermore, the grouting operation is normally also
outside ABB´s undertaking and responsibility.
The installation should be planned as early as possible.
2.3.1 Check of foundation

Before lifting the generator onto the foundation a check should be made to ensure that the
foundation fulfils the following requirements:
• The foundation must be carefully cleaned.
• It must be flat. (If any inclination has been agreed upon the permissible inclination must be
stated on the installation drawing.)
• Check that the position of the anchoring holes and the height of the foundation are in
agreement with corresponding measurements in the inspection and test record, “Magnetic
neutral position”, included in binder “Users Manual”.
• Attach a steel wire to the foundation to indicate the centre line of the generator. Mark also
the axial position of the generator.
3BSY 200016-EYZ 2-16

2.3.2 Vertical and horizontal positioning
CAUTION - Risk of personal injury

Use a piece of carboard to insert the shims under the generator to avoid jamming your
fingers if the jacks should fail.
The vertical positioning of the generator is made with hydraulic jacks (optional equipment)
placed as shown in Figure 2-7 on page 17 and Figure 2-8 on page 18.
ABB AB, Machines´s delivery includes shims with 0.5 and 1 mm thickness, placed as shown in
Figure 2-9 on page 18. Shims needed with other thicknesses are to be provided by the customer.
Bracket plates, (optional equipment) with adjusting screws for horizontal positioning of the
generator are placed at each corners, as shown in Figure 2-7 on page 17.
The bracket plate is to be placed against the foundation edge and the bracket is to be tied down
by using an expansion bolt or welding.
Hydraulic jack
CL
Vertical adjustment
screw, if included
Bracket with
adj. screw
Figure 2-7
3BSY 200016-EYZ 2-17

Hydraulic jack 15t
Elect. machine
max. 79 mm
Foundation
Figure 2-8
Shaft height acc. to outline drwg.
Footplate,
machine
Shims
Footplate in foundation
Figure 2-9
3BSY 200016-EYZ 2-18

2.3.3 Removal of the transport locking device

• The transport locking device is screwed into the shaft on the drive end side of the
generator. The transport locking device consists of a beam, two long bolts and a plate
which lock the rotor against axial movements and rotation. See Figure 2-10 on page 19.
• Remove the screws which are screwed into the shaft. Observe the plate between the beam
and the shaft.
• Loosen the beam from the bolts and remove the bolts from the bearing ring. (Save the
locking device for future needs).
Figure 2-10
3BSY 200016-EYZ 2-19

Chapter 3 Alignment
Chapter 3 Alignment
Introduction
Good planning and preparation result in fast, simple and correct installation. Safe running
conditions with maximum of accessibility are assured.
3.1 Preparations for generator installation

Auxiliary tools for the erection should be made and assembled at site if required:
• Suitable material for set-up and shimming as well as other auxiliary tools for erection are
normally not included in ABB's delivery. (Auxiliary tools for erection, like hydraulic jack
and bracket plates with adjusting screws, can be purchased from ABB as generator
accessory.)
• Attachments for gauges, extension brackets and other alignment tools are to be made.
• Before the rotor is turned, oil must be poured into the bearings, by using an extender
piping connected to the oil inlet pipe on the bearing . The funnel has to be placed above the
bearing as the Figure 3-1 on page 20 shows. The outlet pipe should be open.
Connect to the oil inlet pipe
Figure 3-1.
A simple lever is needed for turning the rotor. While turning the rotor, oil must be continuously
poured into the funnels at both end of the generator.
• If the generator is to be erected outdoors, sun and rain protection must be provided to
eliminate measuring errors.
NOTE: When the surroundings are neither heated nor dry, heating equipment must be
provided.
3BSY 200016-EYZ 3-20

Chapter 3 Alignment
3.2 Rough levelling of generator after erection

Check that the generator is radially and axially level.
Make adjustments by placing shims under the four feet. The generator must be sitting on all
feet on each side.
3.2.1 Rough alignment
Axially
Warning - Heavy lift

The generator is a very heavy unit.
1. Use lifting equipment that is appropriate for the load, see “Technical Specification” for
weight.
2. If the unit has a cooling top, never lift the unit in the lifting ears of the cooling top.
Lift the generator onto the foundation plates as close to the actual position as possible.
The rotor is placed in the magnetic neutral position when the dimension A is fulfilled. Read the
correct distance in the inspection and test record, included in the binder “Users Manual”,
“Magnetic neutral position” (Dimension A). There is also a sign on the bearing house.
NOTE: It is important that the rotor is “IN” the magnetic neutral position when the
generator is in operation.
3.3 Grouting
When the generator has been properly aligned, its base elements are attached to the foundation
by grouting. Use only non-shrinking concrete for grouting to ensure proper adhesion between
the base frame and grouting. Make sure that the grouting fills properly the whole space around
and under the base element. Do not use a vibrator in order to avoid any disturbance in the
alignment.
After the grouting has set (cured), adjust vertically to the final elevation by putting shims
between the base frame and the base element. Check also the other alignments of the generator
and adjust, if necessary.
Non-shrink grout is recommended for the best results. For shaping and grouting, the
manufacturers instructions to be followed.
3BSY 200016-EYZ 3-21

Chapter 3 Alignment
3.4 Correction for thermal expansion

Temperatures have a considerable influence and should be considered during the alignment. The
temperature of the generator is lower during erection than it will be under operating conditions.
For this reason the shaft centre is going to lie higher during operating conditions.
Depending on the type of coupling, the distance between the generator and driven equipment,
etc. compensating alignment may be necessary.
The vertical movement of the shaft of due to thermal expansion the electrical generator is in acc.
to drawing “shaft displacement”, included in the binder “Users Manual”.
3.5 Final alignment and inspection

After the generator has been roughly positioned, as described before, the final alignment can
start.
Lubricate the bearings at regular intervals during the final alignment in accordance with section
3.1 on page 20.
The normal fault tolerance for alignment which ABB accepts is below 0.1 mm at operating
temperature.
Radial misalignment Δr
Gap (angular displacement) Δb
Axial displacement Δa
Figure 3-2.
The tolerances given by the coupling manufacturers must not be used in deciding how accurate
the alignment should be because these tolerances indicate what the coupling can accept.
Excessive tolerances will give rise to vibrations, bearing damage etc. and therefore should
tolerances as narrow as recommended above be aimed at.
Finally check the axial distance between the two coupling halves.
An alignment record should be drawn for future checks.
3BSY 200016-EYZ 3-22

Chapter 4 Mechanical and electrical installation
4.1 Mechanical installation

4.1.1 Cooling arrangement
Air to air
If the cooler housing is delivered separately the following action needs to be taken:
If the cooler top is delivered in separate parts, assemble the parts according to the cooler
supplier’s drawings and manuals included in the binder “Users Manual”.
1. Remove the transport roof on the generator.

The cooler housing is a heavy unit.
1. Use lifting equipment that is appropriate for the load, see “Outline drawing” for weight.
2. Lift the cooler housing over the generator.

3. Lower the cooler housing until it’s almost resting on the generator (if possible), this will
make it easier to adjust the housing to the generator. After all the bolts have been put in
place lower the housing completely and tighten the bolts.
4. The fan motors should be connected according to the circuit diagram (included in binder
“Users manual”). Before the generator is started the direction of rotation of the fans should
be checked against the markings on the cooler housing.
NOTE: Mount the cooler hood to the generator according to instructions and drawings
included in the binder “Users Manual”.
5. Mount the earth strip between the motor housing and cooler top.
6. Mount the hydraulic hose (purge system), with cutting ring and nut, connecting the pipe
from the relief valve with the pipe from the purge unit.
4.1.2 Connection of oil pipes

The bearings are made for flood lubrication, the inlet pipe can be provided with an orifice to
avoid overfilling.
The return pipes should have an incline of 40-50 mm/m in order to guarantee trouble-free oil
circulation. The oil pipes should be designed so that they do not obstruct service and
maintenance. The pipes should be designed so that no stress is applied to the flanges on the
generator.
3BSY 200016-EYZ 4-23

WARNING - Oil leakage

Flushing with the bearings connected might cause oil leakage.
1. Bypass the generator before flushing the oil system.
For required oil flow and pressure see outline drawing. The oil pipes should be carefully flushed
before they are connected to the generator.
4.1.3 Mounting of main terminal box
CAUTION - Component damage

Great care should be taken when handling the main terminal box as it contains delicate
equipment.
To be able to transport the machine the main terminal box for the high voltage connection is
delivered separately and must be fitted at site.
The terminal should be supported so that no stress is applied to the generator.
1. Remove the protection cover fitted over the generator bushings.
2. Level the main terminal box so that no stresses will be induced to the generator bushings
when they are connected to the busbars in the main terminal box.
3. The joint between the main terminal box and the generator should be tightened according
to instruction 3BSM 001263R0001, included in the binder “Users manual”.
4. Before the high voltage cables are connected to the main terminal box the insulation
resistance (megged) should be checked. Check both the generator insulation resistance
(stator winding resistance) and the insulation resistance of the main terminal box
according to instruction in Section 5.3.
5. Tighten the connection of the purging pipes fitted to the main terminal box. Mount the
metal hose and sealing (purge system) between the main terminal box and the cooler top.
4.2 Electrical installation

4.2.1 Connection of control equipment
For terminal box location and content see outline drawing (included in binder “Users manual”).
Connections should be made according to circuit diagram.
NOTE: Space heaters in exciter and stator should be connected as soon as possible after
unpacking. If the permanent supply is not available a temporary supply should be
connected.
3BSY 200016-EYZ 4-24

4.2.2 Connection of high voltage cables

The high-voltage cables are connected according to the terminal markings. Striping, splicing
and insulation of the high voltage cables should be performed according to the instructions from
the cable manufacturer.
The high voltage cables are connected according to the terminal markings. The stator insulation
resistance should be checked before final connection of the cables.
Neutral point connection inside the cubicle.
4.2.3 Earth connection

The earth lead may be connected either inside or outside the terminal box and to both sides of
the generator.
For connection points on the generator see outline drawing (included in binder “Users manual”).
3BSY 200016-EYZ 4-25

Chapter 5 Commissioning
On the commissioning personnel lies a great responsibility for a safe and trouble free operation
of the generator during its lifetime.
Commissioning should only be made by qualified personal.
The following are tests and checks on the generator that are recommended by the manufacturer.
If other tests are to be performed, the manufaturer should be consulted.
5.1 Check of mechanical installation

Check alignment of the generator prior to commissioning.
• Go through the alignment report and ensure that if the generator is accurately aligned
according to ABB AB, Machines´s alignment specifications.
See Chapter 3 Alignment.
• Alignment protocol should always be included in the commissioning report.
Check that the generator is properly anchored to the foundation.

• Check for cracks in the foundation and the general condition of the foundation.
Bearing insulation
• “Megging” of bearings should be performed before the generator is coupled to the
turbine. See section 5.3 on page 28.
Other checks
• Open the generator at both ends and check that no loose parts are present inside the
generator. Check that no parts have come loose during transportation and that the air-gap is
free.
• If possible, turn the rotor and make sure that the rotor turns freely and that no abnormal
sound can be heard. See section 3.1 on page 20.
• Check the airgap between the exciter stator and rotor, see the test record “Air gap
measurement” (included in binder “Users manual”).
WARNING - Magnetic force

There are very strong magnetic forces between the PMG rotor and stator.
1. Remove your own wrist watch, credit cards and other digital equipment before working
around those strong magnetic forces.
Skeleton No. 3BSM005474, Rev. C EN -
2. Personnel with pace maker should not be working in the vicinity of the PMG.
• Check the air gap between the PMG stator and rotor, see the test record “Air gap
measurement” (included in binder “Users manual”).
NOTE: The lubrication system must be commissioned and running before the rotor is
turned.
3BSY 200016-EYZ 5-26

• Check the assembly of the main terminal box and cooling system.
• Check pressure and flow for oil and cooling system according to outline drawing (included
in binder “Users manual”).
5.2 Check of electrical installation

When the stator has been megged (See section 5.3 on page 28) the cables can be permanently
connected to the busbars in the main terminal box.
Check connection of high-voltage cables observing the following.
• Make sure the busbars and insulators do not have any cracks or other damage.
• Check the the bolt connections between stator busbars and terminal box, and make sure it
has been tightened with a torque wrench and that a spring washer has been used.
• Check all busbars, insulators and connections in terminal box.
• Make sure the incoming high-voltage cables are suitably routed and the bracing suitably
carried out.
• Make sure the incoming cables are stress-relieved in a proper way.
• Check phase sequence of incoming cables.
3BSY 200016-EYZ 5-27

5.3 Electrical checks

Bearing insulation resistance check
WARNING - High voltage

This work involves the main circuits of the generator normally connected to the high
voltage supply net. Before you start to work:
1. Make sure the generator is disconnected from the high voltage net and that the circuit
breaker is locked in the open position so it not accidentally (or otherwise) can be closed
during the measurements.
2. Note also that capacitors can contain dangerous voltages, so be sure to ground all details
before you touch them.
All connections of control equipment are to be checked and the function tested.
A bearing insulation check should be carried out before the generator is connected to the
turbine.
Remove the earth cable located on the bearing on the drive end side. Megger the shaft to ground
using no more than 500 Volt DC. See Figure 5-1 on page 28 and Figure 5-2 on page 29.
Loosen the earth cable

before megging.
Figure 5-1
3BSY 200016-EYZ 5-28

Figure 5-2
Insulation resistance is acceptable if the megger value is more than 1 Mohm.
3BSY 200016-EYZ 5-29

General for rotor and stator

The winding shall be dry during the test and therefore the standstill heating elements should
have been active for at least some days before the megging is performed.
The winding temperature should also be recorded. According to normal standards the winding
insulation resistance is to be stated at a winding temperature of 40 o C. The value measured is
therefore converted to a corresponding 40 o C-value, with the help of the following diagram.
Conversion factor, k
100
50
10
0.5
(0.25)-
0.1
0.05
o
-10 0 10 20 30 40 50 60 70 80 90 100 ( C)
Winding temperature
14 32 50 68 86 104 122 140 158 176 194 212 (oF) when meggering
R = Megger-value at a specific temperature
R40 = Equivalent insulation resistance at 40oC
R40 = k x R Example:
R = 30 MΩ measured at 20oC
k = 0.25
R40 = 0.25x30=7.5 MΩ
Recommended minimum insulation resistance at 40oC must exceed the following value
R(40)> U+1 Mohm

Where R(40)= Equivalent insulation resistance at 40 oC.
U = Rated generator voltage in kV (stator or rotor).
The insulation resistance of a new generator, having a clean and dry winding, is considerably
higher as will be found in the test report of the generator.
If the measured value is considered too low the winding must be cleaned and/or dried.
3BSY 200016-EYZ 5-30

Main stator winding insulation resistance check

3. When testing the insulation resistance of the stator winding disconnect the surge
capacitors, lighting arresters and the fuses to the PT’s, if such equipment is installed.
4. If a neutral resistor is installed be sure that it is disconnected.
5. Be sure that the secondary connections of the CT’s and spare cores ARE NOT OPEN.
Megging should be performed in the terminal box and from the synchronizing circuit breaker
(when the high voltage cables has been connected).
If the insulation resistance is low when measuring from the synchronizing circuit breaker,
disconnect high voltage cables and perform the megging direct on the terminals in the terminal
box.
A 5000 Volt DC megger should be used. Reading should be made after 1 minute.
Main stator Polarization Index check

The Polarization Index Test (dielectric absorption test) is an extension of the conventional one-
minute resistance test, where the testing time is extended to 10 minutes. To make the test a
motor-driven or an electronic megger is necessary to give a sufficiently steady voltage during
the testing.
The insulation resistance shall be read every minute.
The ration of the resistance value after 10 minutes to the resistance value after 1 minute is called
the Polarization Index.
R10 R1 = Insulation resistance after 1 - minute

R1 R10 = Insulation resistance after 10- minute
The Polarization Index should exceed ≥ 2.

Field circuit insulation resistance (main- and exciter rotor)
NOTE: For all meggering or HV-tests on rotor see also page 6 in the manual for Telemetry
Unit (ground jumper to be open) included in the binder “Users Manual”.
3BSY 200016-EYZ 5-31

Meggering should be performed at the exciter rotor connection to the main rotor.
A 500 V DC megger should be used. Reading should be made after 1 minute.
NOTE: If 1000V DC megger is used the rectifier has to be short circuit before measuring.
PMG- and Exciter stator winding insulation resistance

A 500 V DC megger should be used. Reading should be made after 1 minute. (When the cables
to the terminal box have been disconnected).
Drying high-voltage windings

The drying process generally takes several days and the insulation resistance, in principle,
follows the curve shown below:
R
(MΩ)
1 2 3 Time (Days)
Figure 5-3
During the drying process it is important that the temperature does not increase too rapidly and
that the final temperature is not too high. The temperature increase may not exceed 5 oC per
hour and the final temperature may not exceed 100 oC. The temperature must be watched
carefully throughout the drying process and the insulation resistance measured at intervals.
When a steady value for the insulation resistance has been achieved, the winding is dry.
Cleaning high-voltage windings

The following cleaning precautions are recommended.
• When the outer casing and winding cover have been dismantled, first remove as much as
possible of the extraneous matter with a paintbrush, stiff brush and a vacuum cleaner. Note
that dirt may be blown into cooling ducts and pockets and lodge there if compressed air is
used.
• If the winding is covered with oil or oil mixed with dust, it should be cleaned using a
suitable solvent: “HAKU 1025/920” (ABB AB, Machines part number: 1245 0011-175),
varnolene or white spirit may be used. Take great care, see manufacturers recommended
precautions.
5.3.1 Start interlocking

If the lubricating or cooling systems are provided with pressure or flow monitors, should these
also be included in the start interlocking systems.
A counter for the number of start up and a duty time meter should be included in the equipment.
3BSY 200016-EYZ 5-32

5.4 Checks during running of the generator

During the first hours/days of running it is important to keep a close surveillance of the
generator in case of any changes in vibration or temperature levels or abnormal sounds should
occur.
Check the connection of oil and cooling water pipes and check for leaks when running the
generator.
5.4.1 Normal vibration levels

The vibration levels given in the table below is intended for protecting the generator from
damage during operation and indicating normal and acceptable levels. Please note that transient
conditions, such as starting or synchronization, are excluded from these recommendations.
Important for vibration monitoring is to detect deviations from normal levels during operation,
and the following guidlines are recommended:
• Set the alarm level at 2 times the normal level during operation
• Set the trip level at 4 times the normal level during operation
The alarm and trip levels should in no case be above what is given in the tables below.
Example: The normal vibration level during operation at site is 1.5 mm/s. The alarm level
should then be set at 3 mm/s, and the trip level at 6 mm/s.
5.4.1.1 Bearing housings
Vertical/horizontal Axial
mm/s in/sec micron mills mm/s in/sec micron mills
rms rms p-p p-p rms rms p-p p-p
Testroom
1.8 0.07 32.4 1.3 2.3 0.9 41.4 1.63
(typical)
Alarm 4.5 0.18 81.0 3.2 7.0 0.28 126.0 5.0
Trip 8.0 0.31 144.1 5.7 15.0 0.59 270.1 10.6
Table 5-1: Acceptable vibration levels for bearing housings. The values are valid for all speeds.
(Measured frequency range 10-1000 Hz)
3BSY 200016-EYZ 5-33

5.4.1.2 Structural vibrations

The following values are valid for structural vibrations in the supporting structure of the
generator, covers etc are excluded.
Vertical/horizontal Axial
mm/s in/sec micron mills mm/s in/sec micron mills
rms rms p-p p-p rms rms p-p p-p
Testroom
4.5 0.18 81.0 3.2 4.5 0.18 81.0 3.2
(typical)
Alarm 7.0 0.28 126.0 5.0 11.0 0.43 198.1 7.8
Trip 15.0 0.59 270.1 10.6 20.0 0.79 360.1 14.2
Table 5-2: Acceptable vibration levels for supporting structures. The values are valid for all
speeds. (Measured frequency range 10-1000 Hz)
5.4.1.3 Shaft vibrations

The following values are valid for shaft vibrations measured with eddy-current probes.
Vertical/horizontal
mm/s in/sec micron mills
rms rms p-p p-p
Testroom
- - 50.8 2.0
(typical)
Alarm - - 76.2 3.0
Trip - - 101.6 4.0
Table 5-3: Acceptable vibration levels for shaft vibrations. The values are valid for all speeds.
5.4.2 Temperature levels

The temperatures of the bearings and stator winding and air should be checked when the
generator is running for the first time.
The bearings reach a stable temperature after about 45 to 60 minutes when running at full speed
if the temperature of the oil to the bearings is about 40 oC.
The stator winding temperature depends on the load of the generator. If full load cannot be
obtained during or soon after commissioning, the present load and temperature should be noted
and included in the commissioning report.

Recommended settings for alarm and trip levels, see the test record “Setting List” included in
the binder “Users manual”.
3BSY 200016-EYZ 5-34

5.5 Check list

The following checklist and protocols should be completed during commissioning and returned
to ABB AB, Machines toghether with the commissioning report after completed
commissioning.
Checks to be made during operation, please see Chapter 6 Operation.
3BSY 200016-EYZ 5-35

5.5.1 Page 1
Customer: Name and company of responsible commissioning engineer:
Site name:
Serial number:
Order number: Date:
o First run up, date .....................................

o Direction of rotation: clockwise (Seen from D-end)
o Direction of rotation: counterclockwise (Seen from D-end)
o No abnormal noise
Comments ...............................................................................................................................................................
................................................................................................................................................................
o Second run up (to full speed), date ................................

Starting time ............................. s
Retardation time .................. min
Comments ...............................................................................................................................................................
...............................................................................................................................................................
Generator data
Output: kVA Power factor: Voltage: V
Frequency: Hz Speed: r/min Current: A
Excitation: V A Oil quality:
3BSY 200016-EYZ 5-36

5.5.2 Page 2
Site name:
Serial number:
Order number: Date:
Time Bearing temp. Inlet Oil Vibr. Winding Cooling Comments

o
( C) (mm/s, μm) temp. air/water Vibrations, noise, etc.
(oC)
D- N- (oC) (l/s) D- N- max min m3/h o

C
side side side side
3BSY 200016-EYZ 5-37

5.5.3 Page 3
Site name:
Serial number:
Order number: Date:
Time Stator Exciter Load Comments

Field (A) (MW) Vibrations, noise, etc.
(A) (cosϕ) (V)
3BSY 200016-EYZ 5-38

Chapter 6 Operation
Chapter 6 Operation
6.1 Start up procedure

Before start up of the generator a check has to be made that:
– Beware that all protection covers and other equipment is correctly installed and that no
person is close to voltage carrying equipment or rotating parts.
– Authorization has been given to start and that there is no risk of personal or property
damage.
– Required oil supply is fulfilled in accordance to drawing “Outline synchronous generator”,
– Required cooling media is fulfilled in accordance to drawing “Outline synchronous
generator”.
– No shut down means are in operation.
– Personnel and equipment associated to the generator are ready for start up of generator.
6.2 Continuous supervision

The operating personnel should inspect the generator at regular intervals.
This means that they should listen, feel and smell the generator and its associated equipment in
order to obtain a feeling for normal operating condition.
The object of the supervision inspection is to thoroughly familiarize personnel with the
equipment. This is imperative if abnormal occurrences are to be detected and remedied in time.
It is therefore recommended that a “supervision inspection sheet”(attached) will be filled in.
Data from a supervision inspection should be kept for future reference and can be of great help
at maintenance work, trouble shooting and repairs.
The programme for suitable supervision inspections can be found below.
The border between supervision and maintenance is rather diffuse. Normal supervision of
operation includes logging of operating data such as load, temperatures etc., and the comments
made are used as a basis for maintenance and service.
• During the first period of operation (- 200 hours) supervision should be intensive.
Temperature of bearing and winding, load, current, cooling, lubrication and vibration shall
be checked frequently and logged.
• 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 with the customer. Thereafter the
time between inspections may be further extended if operation is continuous and stable.
3BSY 200016-EYZ 6-39

Chapter 6 Operation
6.3 Shut down procedures

During shutdown of the generator, lubrication oil and cooling media supply has to be ensured.
When the generator not is in operation, the anticondensation heaters to be switched on. Those
actions are to be made to avoid condensation within the generator
6.4 Alarm during operation

If alarm during operation e.g.:
• Cooling
• Water
• Lubrication
• Temperature
• Vibration
• etc.
The generator has to be unloaded and deenergized (triped).
After coasting down the generator make necessary investigation to find out the reason for the
alarm before next start.
3BSY 200016-EYZ 6-40

Chapter 6 Operation
RECOMMENDED SUPERVISION INSPECTION SHEET (2 pages)

Site name:
Serial number:
Order number: Date:
Time Bearing temp. Inlet Oil Vibr. Winding Cooling Comments

(oC) (mm/s, μm) temp. air/water Vibrations, noise, etc.
(oC)
D- N- (oC) (l/s) D- N- max min m3/h o

C
side side side side
3BSY 200016-EYZ 6-41

Chapter 6 Operation

Site name:
Serial number:
Order number: Date:
Time Stator Exciter Load Comments

Field (A) (MW) Vibrations, noise, etc.
(A) (cosϕ) (V)
3BSY 200016-EYZ 6-42

Chapter 7 Maintenance
7.1 Preventive maintenance

A generator often forms an important part of a larger installation and if it is supervised and
maintained properly it will be much more reliable in operation.
The border between supervision and maintenance is rather diffuse. Normal supervision of
operation includes logging of operating data such as load, temperatures etc., and the comments
made are used as a basis for maintenance and service.
After commissioning or maintenance supervision should be intensive. Temperature of bearing
and winding, load, current, cooling, lubrication and vibration shall be checked frequently.
Local condition has to be considered when decision of maintenance interval and level.
7.2 Before all maintenance work

Safety precaution
WARNING - Risk of personal injury

Before any maintenance or tests is performed the following must be done:
1. The generator must be completely stopped, dead, disconnected and grounded before any
inspection covers are opened on the generator.
2. Before working on any electrical equipment, general electrical safety precautions are to be
taken and local regulation has to be respected, according to instructions of the customers
personnel in charge of security, in order to prevent personnel accidents.
3. Employees who perform maintenance on electrical equipment and installations shall be
qualified persons as required, and shall be trained in and familiar with the specific
maintenance procedures, and the tests required.
Preparation and preplanning of maintenance

Preparation and preplanning is recommended before all maintenance, special level 3 and 4.
Requirements of:
• Lifting capacity.
• Tools including rotor removal at level 4.
• Manpower and needed competence.

• Spare parts and other overhaul kit (replacement and consumables).
3BSY 200016-EYZ 7-43

7.3 Recommended maintenance program

Maintenance
Level 1 (L1) Level 2 (L2) Level 3 (L3) Level 4 (L4)
program
max. 10 000h (equivalent max. 20 000h (equivalent max 40 000h (equivalent max 80 000h (equivalent
Interval hours) of operation hours) of operation hours) of operation hours) of operation
or yearly or max. 3 years or max. 6 years or max. 12 years
Preparation for Open inspection covers. Open inspection covers. Disassembly PMG stator. Open bearings.
inspection Open bearings. Removal rotor
and exciter.
Instrument/ Megger, stator. Megger, stator Megger, stator.
Tools Megger, rotor. Megger, rotor Megger, rotor.
Fibre-optic or video Rotor removal equipment.
borescope. Torque wrench.
Oscilloscope/Test Oscilloscope/Test
equipment. equipment.
Parts/ Bearing shell, Acc. to L1 and suggestion Acc. to L2 and suggestion Acc. to L3 and suggestion
Spare parts Brushes, from inspection L1. from inspection L1 and from inspection L1, L2
Shaft seals, Silicon tape. L2. and L3.
Airlock filter (bearing), Rectifier kit. Rotor kit.
Control pulse unit, Bearing kit.
Thyristors, Diodes. Gaskets.
Other order specific
parts.
Expected Approx. 1 day. Approx. 2 days. Approx. 5 days. Approx. 10 days.
downtime
Option: Diagnostic insulation test of the stator winding.
Equivalent hours = Total operation hours + No of starts x 20
Example of maintenance schedule:
Interval 10 20 30 40 50 60 70 80
Hours x 1000
Program L1 L2 L1 L3 L1 L2 L1 L4
Timing of the inspection and overhauls are largely determined by the number of operating hours, the mode of operation and
the number of starts of the generator. Local condition has to be considered.
The maintenance intervals shall be co-ordinated for the generator, in a suitable way.
3BSY 200016-EYZ 7-44

7.3.1 Generator
Location L1 L2 L3 L4 Activity Approved
1. Generator X X X X 1. Look through all logged or recorded data available;

load, temperature, vibrations etc. Fill in the report. If
values deviate from time of commissioning or earlier
inspection please contact the supplier.
X X X X 2. Inspect exterior of generator for rust, leaks or other
defects.
X X X X 3. Check tightness of all fastenings.
X X X X 4. Replace air filter, if necessary.
X X X X 5. Ensure ventilation ducts are clean and free of obstruction
if connected to external air.
2. Foundation X X 1. Inspect grouting and anchored bolts. Check for excessive
clearances and correct as required. Inspect for cracks in
the foundation.
3. Service/Repair X X 1. Replacing, cleaning and modification acc to
recommendation in earlier inspections and suppliers
service bulletin.
General cross-
section AMS
machine (actual
design acc. to
outline included in
binder “Users
Manual”).
Inspection covers
on both ND- and
D-end sides.
Figure 7-1
3BSY 200016-EYZ 7-45

7.3.2 Stator
1. Stator winding X X X X 1. Inspect winding connections.

X X X X 2. Inspect winding and bracing rope.
X X 3. Inspection for cleanliness, discoloration, condition of
insulation, looseness, movement and wear.
Clean if necessary.
X X X 4. Measure and record insulation resistance. Refer to
instruction “Commissioning” section “Electrical checks”,
X X X 5. Measure Polarization Index. Refer to instruction
“Commissioning” section “Electrical checks”, included
in the binder “Users Manual”.
2. Air cover X X X X 1. Check sealing.
3. RTDs X X X X 1. Verify function of all RTDs.
4. Heaters X X 1. Function check.
Air cover
Sealing Air cover
Stator coils
Bracing rope
Figure 7-2
3BSY 200016-EYZ 7-46

7.3.3 Stator terminal

Terminal box X X X X 1. Check all line- and neutral connections.

X X X X 2. Check general condition.
X X 3. Check tightening torque at all connections and insulation
behind the terminals.
X X 4. Test e.g. Current transformers (CT), etc. if applicable.
Terminal box for the generator, see drawing 3BSY 202103-EYZ.

3BSY 200016-EYZ 7-47

7.3.4 Rotor
1. Rotor X X 1. Check all brazed connections for cracks.

X X X 2. Measure field circuit insulation resistance, 500V DC
megger. Refer to section 5.3.
2. Rotor coils X X X X 1. Check turn insulation, discoloration etc.
X X 2. Check interconnections.
X X 3. Check turn insulation (voltage drop test).
Refer to section 7.4.
3. Rotor coil X X X X 1. Inspect coil supports, screws, washers and insulation.
support
X X 2. Check upper coil support insulation plate, Max.
movement, 10mm radially out of original position.
Brazed connection Rotor coils

Connection rotor and
exciter rotor Interconnection Lower coil support
Upper coil support

Insulation plate
Figure 7-3
3BSY 200016-EYZ 7-48

4. Pole shoes X X X X 1. Check pole shoes for discoloration.

5. Pole bolts X 1. Inspect by knocking on bolt head.
If pole bolts are loose or corroded, ABB has to be
contacted.
6. Fan X X 1. Inspect fan blades and weldings.
7. Balancing X X 1. Inspect balancing weights and fastening details.
8. Air gap X 1. Check air gap after assembling of machine.
Fan
Balancing weights
Pole bolts
Pole shoes
Figure 7-4
3BSY 200016-EYZ 7-49

7.3.5 Bearings
1. Bearing X X 1. Open bearings.

inspection
2. Bearing X X X X 1. Inspect for leaks.
housing and
X X X X 2. Inspect all bolted joints.
support
X X X X 3. Inspect guide support.
3a. Shaft seals X X X X 1. Check for leaks. If leaks are found, check for wearing and
damages.
X X 2. Clean drain holes in the shaft seals.
3b. Sealing in air
lock cover X X 3. Check for leaks. If leaks are found, check the sealing.
4. Shaft surface X X 1. Verify that the sealing surface is free from corrosion and
wearing.
5. Bearing X X 1. Measure insulation resistance. Refer to section 5.3.
insulation
6. Oil ring X X 1. Check for wearing or damages.
7. Oil piping X X X X 1. Inspect for leaks.
8. Measuring X X X X 1. Verify function of all measuring instrument.
instrument
9. Lube oil X X 1. Analyse oil for contamination and replace oil and clean
the system if necessary. Refer to section 7.5.3.
2. Check for water in each bearing and remove if necessary.
10. Air filter X X X X 1. If necessary replace filter for air intake to the airlock
seals, located on bearing pedestals.
Oilring Airlock cover

Fore bearing seal Sealing in airlock cover
Bearing shell
Rear bearing seal

Bearing housing
Baffle or
Tightening cover
Figure 7-5
3BSY 200016-EYZ 7-50

7.3.6 PMG (Permanent magnetic generator)

1. Be extreamly careful when removing the PMG stator housing to avoid damage to
components due to magnetic forces.
2. Remove your wrist watch, credit cards and other digital equipment before working around
those magnetic forces.
.
1. PMG Stator X X 1. Visual inspection.

X X X 2. Measure insulation resistance, 500V DC megger. Refer to
section 5.3.
2. PMG Rotor X X 1. Visual inspection.
3. Air gap X X 1. Check air gap.
PMG stator
PMG rotor
Permanent magnets
Figure 7-6
3BSY 200016-EYZ 7-51

7.3.7 Exciter and Rectifier

1. Exciter Rotor X X X X 1. Visual inspection.

section 5.3.
2. Diodes, X X 1. General cleaning.
thyristors
X X 2. Check all bolts fastening.
X X 3. Inverse voltage test. Refer to section 7.5.1.
3. Control pulse X X 1. Check wiring to and from the unit.
unit (Rectifier)
X X 2. Check firing level. Refer to section 7.5.1.
4. Rotor X X 1. Check all connections to the exciter.
terminals
5. Exciter stator X X X X 1. Visual inspection.
section 5.3.
6. Air gap X X 1. Check air gap.
7. Heaters X X 1. Function check.
Exciter stator
Exciter rotor
Rectifier
Connection rotor and

exciter rotor
Figure 7-7
3BSY 200016-EYZ 7-52

7.3.8 Cooling system

For maintenance of cooler and fans see manual included in the binder “Users Manual”.
If temperature detectors show normal temperature, usually no additional maintenance to
supervision inspection is required for the cooling system.
If temperature detectors show an abnormal temperature, or close to alarm level, in winding or
cooling air a check of the cooling system has to be made.
7.3.9 AVR (Automatic Voltage Regulator) and

Generator Protection System
Have to be checked regarding settings and function of trip signals. See separate instructions
from supplier.
7.3.10 Purge system

For maintenance instructions, refer to manual included in “Users manual” section “Accessories
& Instructions”.
7.4 Main rotor coil turn insulation (voltage drop test)
WARNING - Electricity 230 V or 400 V 50 Hz / 208 V or 480 V 60 Hz

During the voltage drop test there is a AC-voltage over the field windings. Be carefull so
no personal injury occur.
1. Connect all measuring cables before start of measurement.
2. Connect a earth current circuit breaker as protection.
The test is carried out by applying an AC-voltage over the entire field winding and measuring
the current and the voltage drop across the total winding as well as each single coil, see figure
7-8.
The applied voltage should be 230 V or 400 V 50 Hz / 208 V or 480 V 60 Hz depending on the
rated frequency of the machine.
+ ΔU1
The voltage over a single coil (ΔU) should
ΔU
not differ more than ±3% from U/4.

2
U
ΔU
ΔU4
3
-
Figure 7-8
3BSY 200016-EYZ 7-53

7.5 Fault finding

The generator is protected with alarms and trips for most kinds of abnormal running conditions,
both electrical and mechanical. Some of these protections can be reset and the generator
restarted directly as the fault is known or easy to locate.
Examples of protections that if they give an alarm or trip, may need further investigations to be
located are:
• Diode fault protection.
• High temperature in bearing.
• High temperature in winding or in cooling air.
• Vibration protection.
7.5.1 Diode fault

In case any of the diodes or thyristors in the rotating rectifier should fail, the “diode fault”
protection will pick up and trip the generator. To determine and locate a faulty diode, open the
cover of the rotating rectifier and measure with an ohm-meter over one of the diodes or
thyristors. If a faulty diode or thyristor is detected, disconnect all diodes and test them
separately to locate the faulty diode.
NOTE: If a faulty diode or thyristor the recommendation is to replace all diodes,

thyristors and control pulse unit.
Refer to the instruction “Replacement of diodes and thyristors” included in the binder “Users
Manual”.
To test the thyristors, firing unit and diodes the following method can be used:
• Open the cover of the rotating rectifier.
• Disconnect the rotor winding from the rectifier.
• Apply alternating voltage to the plus and minus bars of the diode bridge according to
figure 7-9. A 600 ohm resistor shall be connected to limit the current flow as shown in
figure 7-9.
Note: An equipment specially made for this test is possible to buy from ABB AB, Machines.
Test equipment - Rectifier unit
Supply
Exciter
voltage osc side
Uac
≈ 600 Ω
+
Figure 7-9
• Increase the voltage and check with an oscilloscope the triggering voltage level of the
firing unit and the thyristors as shown in figure 7-10 chart 2 and 3.
3BSY 200016-EYZ 7-54

• Decrease the voltage to a level under the firing units trigger level, see figure 7-10 chart 1
and measure over each diode separately. A shorted diode will show zero (0) volt on the
oscilloscope.
Test result for healthy rectifier
1. Û< Triggering voltage level Ûac < UT

Triggering voltage UT
level
Test Voltage
Ûac
2. Û = Triggering voltage level Ûac = UT
UT
Ûac
3. Û > Triggering voltage level Ûac > UT
UT
Ûac
Figure 7-10
3BSY 200016-EYZ 7-55

7.5.2 Altering the firing voltage

To alter the firing level on the control pulse unit, the cable have to be connected to the terminal
corresponding to the new firing level.
NOTE: Before altering the firing level, write down the original connections for firing
level, thyristors, etc.
Thyristor B Thyristor A
K K-G K K-G +
150V
225V
300V
450V
600V
750V
900V
1.1kV
1.3kV
1.5kV
x Drawing number
Seriel number
x
Connect to right firing level
Figure 7-11
3BSY 200016-EYZ 7-56

7.5.3 Lubrication
The generators are provided with sleeve bearings with an almost unlimited service life provided
that the lubrication functions continuously and that the oil is changed at suitable intervals.
Temperature
To enable the bearing temperature to stabilize at a normal level, the correct amount or flow of
oil is required. The normal bearing temperature is 65 - 85 oC.
NOTE: The oil may be warm.
Characteristic properties of the oil qualities listed are:

The oil is a lubricant based on paraffin having high viscosity coefficient (VI>90) and a
particularly low fluid temperature. It includes the following additives:
• oxidation inhibitor
• anti-foaming
• mild EP action, anti-wear additive
• rust inhibitor
Condition of the lubricant

Check the oil with respect to colour, smell, turbidity and deposits in a test bottle.
The following requirements shall be fulfilled:
• The oil should be clear or negligibly turbid. The turbidity may not be caused by water.
• Strong acid or burnt smell is not acceptable.
• The quantity of metal impurities may not exceed 0.05% by weight.
• The original viscosity must be maintained within a tolerance of ±10-15%.
• The original acid number should not be exceeded by more than 1 mg KOH per gram oil.
An oil check should be performed a few days after the first test run of the generator and
subsequently as required. If the oil is changed just after the commissioning, it can be used again
after removing wear particles by filtering or centrifuging.
In doubtful cases an oil sample may be sent to the laboratory to determine viscosity, acid
number, foaming tendency, etc.
A duty period of 3-8 years before an oil change is necessary is not unusual.
3BSY 200016-EYZ 7-57

Oil qualities
Unless otherwise stated on ABB AB, Machines drawing “Outline synchronous generator”
included in the binder “Users Manual”, the bearings are designed for any of the following oil
qualities:
Oil 7 1201-301 (Oil 7061)

ISO VG 32
Viscosity 32 cSt at 40°C (20 at 50°C)
Pour point max. -30°C.
BP: Energol HLP 32
Castrol: Hyspin AWS 32
Esso: Nuto HP 32
Gulf: Harmony 32 AW
Klüber: Lamora 32
Mobil: D. T. E. 24
Optimol: Ultra 5025
Shell: Tellus Oil 32
Texaco: Rando Oil HD A 32
Oil 7 1201-302 (Oil 7071)

ISO VG 46
BP: Energol HLP 46
Esso: Nuto HP 46
Gulf: Harmony 46 AW
Klüber: Lamora 46
Mobil: D. T. E. 25
Optimol: Ultra 5035
Texaco: Rando Oil HD B 46
Oil 7 1201-303 (Oil 7081)

ISO VG 68
BP: Energol HLP 68
Esso: Nuto HP 68
Gulf: Harmony 68 AW
Klüber: Lamora 68
Mobil: D. T. E. 26
Optimol: Ultra 5045
Texaco: Rando Oil HD C 68
3BSY 200016-EYZ 7-58

7.5.4 High temperature in bearing
7.5.4.1 Trouble shooting 1

Customer : .......................................................................................................................................
Machine type : .......................................................................................................................................
Machine serial no : .......................................................................................................................................
Insufficient section 7.5.4.2

lubrication
Oil temperature Faulty oil cooler Replace the

too high cooler
High axial forces Faulty coupling
Faulty assembled Has bearing been Open and adjust

bearing disassembled?
Damaged part of Impurities in the Change oil

babbits oil?
Inductive bearing Repair bearing

currents? insulation
Complete seizure Repair bearing

of bearing journal
Replace
bearingshell
Faulty
instrument?
3BSY 200016-EYZ 7-59


Customer : .......................................................................................................................................
Machine type : .......................................................................................................................................
Oil pump not generator Fault finding

reliable? protection trips? and action
Low Oil filter Check main-

oil flow clogged? tenance status Replace filter
Reduction valve Latest

Adjust flow
shut? adjustment?
Too low oil Faulty oil Fault finding

temperature heater and action
Check with
Unsuitable oil Change oil
ABB AB,
quality Machines´s quality
recommendation
Oil Check status of

worn out oil change Replace the oil
3BSY 200016-EYZ 7-60


Customer : .......................................................................................................................................
Machine type : .......................................................................................................................................
Oil worn out Replace the oil

Unstable bearing
temperature
Impurities in the
Replace the oil
oil
Damaged shaft
Repair the seals
seals
Airlock seal out Repair/replace

of action the airlock cover
Oil leaks
Too high oil
flow Correct oil flow
Incorrect
Problem in oil
inclination of
flow return
the return pipe?
Check for fault

in external oil
Check for supply system
under/over
pressure in
Check that
bearing under pressure
is well below
surrounding
outside the
bearing housing
3BSY 200016-EYZ 7-61

7.5.5 High winding and / or air temperature
7.5.5.1 Trouble shooting

Customer :.......................................................................................................................................
Machine type :.......................................................................................................................................
Machine serial no :.......................................................................................................................................
Faulty
Faulty sensor
instrument
Low cooling air

flow
Cooling air
temperature to
high
High winding and/or
air temperature
Dirty or plugged Clean the
filter/airduct filter/airduct
Overload
Dirty stator Clean the stator

3BSY 200016-EYZ 7-62

Chapter 8 Disposal and Recycling
8.1 General
The manufacturing process of the machine is carried out in accordance with the Environmental
Management System ISO 14001.
This instruction concerns the disposal and recycling of Large AC-machines. The machines are
designed in a way that it is easy to separate the different components and types of material from
eachother, making it esier to recycle.
NOTE: The methods are described in a very general way. All instructions are to be
performed by personnel which is trained and skilled for the procedure.
8.2 Dismantling the machine
Warning - Heavy components

Risk of personal injury when dismantling the machine.
1. Only skilled and trained personnel should carry out the dismantling.
Dismantling the machine is done by simply separating all the components of the machine. Since
the machine mainly is assembled with screws and nuts, it is rather simple to carry out the
dismantling. When the machine has been dismantled into its different components, the different
components has to be separated and grouped together dependent upon the different types of
material.
8.3 Separation of different types of material
8.3.1 Normal carbon steel

The following components is separated into one group for normal carbon steel:
• Rotor body
• Stator ends
• Bearing supports
• Foot plates
• Encapsulation
• Side plates
• Roof
3BSY 200016-EYZ 8-63

• Oil tubes from the lubrication system.

If the tubes are made of stainless steal, it is necessary to separate them from the rest of the
steel components. If not the stainless steel will cause a very low quality of the total steel
collected - it is a poison for the steel manufacturer.
• Teminal box with the copper separated
• Bolts and nuts
• etc ... etc.
8.3.2 Electrical silicon steel non oriented

The following components is separated into one group for electric silicon steel non oriented:
• Stator lamination
• Lamination of the exciter stator
• Lamination of exciter rotor.
These laminations are welded to respective components and can be separated with a gas burner.
8.3.3 Special high quality steel

The following component is separated into one group for special high quality steel:
• Pole tips of the rotor.
8.3.4 Mixed metallic material

The following components are separated into one group for mixed metallic material:
• Coolers.
The coolers often contains Cu/Ni tubes or stainless steel tubes. In the cases of stainless steel
these may be separated by using a gas burner or similar and collected in the group for stainless
steel. The rest of the cooler may be considered as mixed material.
8.3.5 Stainless steel

The following components are separated into one group for stainless steel:
• Oil tubes from the lubrication system.
If the tubes are made of stainless steal, it is necessary to separate them from the rest of the
steel components. If not the stainless steel will cause a very low quality of the total steel
collected - it is a poison for the steel manufacturer.
• Tubes from coolers. See Section 8.3.4 Mixed metallic material.
8.3.6 Cast iron

The following components are separated into one group for cast iron:
• Bearing housing
• Bearing spheres.
3BSY 200016-EYZ 8-64

8.3.7 Aluminium
The following components are separated into one group for aluminium:
• Coil supports of the rotor
• Heat sinks for thyristors and diodes in the exciter.
8.3.8 Copper
Copper is mostly integrated in the actual components and require some effort in order to be
separated. There exist some special tools for making the separation but normally wedges, large
hammers, gas burners and manpower is used.
The following components are separated into one group for copper:
• Stator coils
The copper is integrated in the stator and is glued to the stator by use of an impregnation
resin. Thereafter the copper in the stator is surrounded by several mm of micabased
insulation. The separation of copper from the insulation is done by the method granulation,
which is used by larger recycling companies. The granulation method cuts the copper into
pieces and the copper is then separated from the insulation by a mechanical process. This
can also be done by manpower using hammer and wedges. The amount of copper in the
stator is large.
• Stator connection
The copper is integrated within the stator winding. It may be cut off and separated from its
insulation by granulation or by manpower.
• Rotor coils in the machines rotor
This is clean copper mixed together with layers of insulation. It may be separated from the
rotor by loosening the pole bolts of the rotor body and by removing the coil supports. This
copper is of high quality and value, and the amout is large. The copper from the rotor coils
is to be kept separate from all insulated copper.
• Rotor connections in the machines rotor
This is cable copper that may be separated from the rotor by a gas burner combined with
manpower.
WARNING - Dangerous gas

This method is only to be performed in an oven with proper filters in order to prevent
hazardous emissions to enter the air.
It might come off easier if first heating up the rotor until the epoxy resin within the rotor
shaft is carbonised.
• Clean copper in the terminal box

This is the best quality of copper and has to be separated from all types of insulated copper.
• Stator coils in the exciter stator
This is enameled copper that is glued together with the stator by impregnation resin. It may
be separated from the exciter stator by manpower or by using special equipment.
3BSY 200016-EYZ 8-65


This metod is only to be performed in an oven with proper filters in order to prevent
It might come of easier if first heating up the stator until the impregnation resin is
carbonized.
• Rotor coils in the exciter rotor
This is enammelded copper that is glued together by impregnation resin. It may be
separated from the exciter by manpower or using special equipment.

This metod is only to be performed in an oven with proper filters in order to prevent
It might come of easier if first heating up the rotor until the impregnation resin is
carbonised.
8.4 Waste as land fill

All inslulation material is not to be considered as hazardous waste. It may be used as land fill or
sent to power plants to be burned.
NOTE: Make sure the power plant is adapted for this kind of fuel and have the proper
types of filter etc. in order to prevent gases and dust to enter the environment.
8.5 Hazardous waste

The oil from the lubrication system is to be considered as hazardous waste and have to be taken
care of according to regulations. The oil is to be sent for destruction or to be burned in specially
prepared power plants.
8.6 Final comments

If there is some questions of enviromental matters not considered in this instruction we ask the
user to get in contact with the Environmental Coordinator of the Machine Division.
3BSY 200016-EYZ 8-66

3BSY 200016-EYZ
2007-10-25
Service & Repair 6\QFKURQRXVPDFKLQH
Replacement of diodes and thyristors
Document No.:3BSM 005449
Contents
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1.1 General safety instructions ............................................ 3
&KDQJHRIGLRGHVDQGWK\ULVWRUV
2.1 Dismantling of diode and thyristor ................................ 4
2.2 Assembling of diode and thyristor................................. 7
2.3 Change of control pulse unit........................................ 10
2.4 Recommended tightening torque for bolts ...................11
6\QFKURQRXVPDFKLQH
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The information in this document is subject to change without notice and should not be construed as a commitment by ABB.
ABB assumes no responsibility for any errors that may appear in this document.
This document and parts thereof must not be reproduced or copied without ABB’s written permission, and the contents thereof
must not be imparted to a third party nor be used for any unauthorized purpose.

3BSM 005449, Rev. B EN -
3BSM 005449 ii
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The procedures described in this manual are only to be performed by trained personnel
authorized by the user.
The manufacturer is not responsible for malfunctions that comprise safety as a result of
alteration, use of non ABB replacement parts, neglect or misuse.
Replacement parts may vary from those shown in this manual. Should you have questions on
those parts please contact ABB Automation Technologies AB.
The actual appearance of the machine may vary from the illustration in this manual.
be used until testing and analysis demonstrate that the equipment meet the original or upgraded
specifications.
hazards. The recommended precautions and procedures of the manufacturers should be
followed.
3BSM 005449, Rev. B EN -
3BSM 005449 3
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1. Be extremely careful when removing the PMG stator frame. There are very strong
magnetism to avoid, and prevent damage to components due to magnetic forces.
2. Remove your own wrist watch, credit cards and digital equipment before working around
those strong magnetic forces.
3. Personnel with pace maker should not be working in the vecinity of the PMG.
'LVPDQWOLQJRIGLRGHDQGWK\ULVWRU
When dismantling of thyristor: Disconnect the cable from the control pulse unit. Observe the
connection of the cable to the control pulse unit. The new thyristor should have same connection
during assembly procedure.
Loosen the assembly brack from the connection bar and remove the two plastic plugs (one on
each screw). See Figure 2-1 on page 4 and Figure 2-2 on page 5.
3BSM 005449, Rev. B EN -
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3BSM 005449 4
6\QFKURQRXVPDFKLQH
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Open the spring lock as shown in Figure 2-3 on page 5 and Figure 2-4 on page 6 at the assembly
bracket by using a screw driver.
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3BSM 005449, Rev. B EN -
3BSM 005449 5
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Loosen the hex. head socket cap bolts while pushing out the spring lock. Loosen the bracket so
much that the diode/thyristor can be removed. See Figure 2-5 on page 6.
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3BSM 005449, Rev. B EN -
3BSM 005449 6
6\QFKURQRXVPDFKLQH
Observe and write down the direction of the black arrow on the front of the diode/thyristor. The
replacement diode/thyristor must point in the same direction during assembly procedure, see
Figure 2-6 on page 7.
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Thyristor connections (wires) must be soldered as shown in Figure 2-7 on page 7 to ensure safe
operating conditions.
3BSM 005449, Rev. B EN -
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Put a protective sleeve over the cable and a pin in the end of the cable. Connect the cable to the
control pulse unit at same place as before.
3BSM 005449 7
6\QFKURQRXVPDFKLQH
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Clean the contact surface between the diode/thyristor and the assembly bracket, and the contact
surface between the diode/thyristor and the heat sink with a piece of cloth damped in
ACETONE. See Figure 2-8 on page 8.
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Clean the contact surfaces of the new diode/thyristor by using steel wool and a cloth damped
with ACETONE. See Figure 2-9 on page 8 and Figure 2-10 on page 9.
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3BSM 005449, Rev. B EN -
3BSM 005449 8
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Apply a thin coat of Silicon grease to both sides (contact areas) of the diode/thyristor.
Place the diode/thyristor back between the heat sink and the mounting bracket.
Rotate the diode so that the arrow marking of the diode/thyristor is visible at the front . Check
that the black arrow on the diode/thyristor points in the same direction as the one that was
removed earlier. See Figure 2-11 on page 9.
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Be careful that both guide pins (roll pins) are in place before tightening bolts.
Tighten the screws carefully one at the time so that the mounting bracket applies an even
pressure to the diode.
A spring is attached on the mounting bracket which snaps in place when the right torque is
3BSM 005449, Rev. B EN -
reached (note that in the dismantling mode, the screw driver was used to remove this spring to
permit loosening of the screws). Use a “dentists mirror” (a mirror with a handle) behind the
spring to check that the spring has snapped in place. Check with the mirror that there is no
3BSM 005449 9
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visible gap between the spring and the mounting bracket body. The spring must be in place
before the assembly is completed. See Figure 2-12 on page 10.
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Replace the plastic plugs.
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Disconnect the thyristor cables.
Loosen the two bolts which attaching the control pulse unit to the exciter hub, see Figure 2-13
on page 10.
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3BSM 005449, Rev. B EN -
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For reassembly, mount the components in the reverse order.
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Recommended tightening torque for bolts property class 8.8, slightly coated with oil.
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%ROWVL]H 0 0 0
7RUTXH (Nm) 22.5 45 79

(lbft) 16.6 33 58
%ROWVL]H 0 0 0 0
7RUTXH (Nm) 190 420 735 1500

(lbft) 140 300 550 1100
3BSM 005449, Rev. B EN -
3BSM 005449 11
3BSM 005449
2003-01-15
Service & repair Synchronous machine
Dismantling and assembly of the rotor
earth fault detection system and the
PMG-stator
Document No.:3BSM901594
Contents
1 - Safety
1.1 General safety instructions................................ 3
2 - Dismantling and assembly of the rotor earth

fault detection system and PMG-stator
2.1 Dismantling of the rotor earth fault detection
system ............................................................... 4
2.2 Dismantling of PMG stator............................... 6
2.3 Assembly of PMG stator................................... 9
2.4 Assembly of telemetry .................................... 12
2.5 Recommended tightening torque for bolts...... 13
Synchronous machine
NOTICE
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.

3BSM901594, Rev. - EN
3BSM901594 ii
Synchronous machine
Safety
1 Safety
1.1 General safety instructions

those parts please contact ABB AB, Machines.
specifications.
followed.
3BSM901594, Rev. - EN
3BSM901594 3
Synchronous machine
Dismantling and assembly of the rotor earth fault detection system and PMG-stator
2 Dismantling and assembly of the rotor earth fault detection

system and PMG-stator
2.1 Dismantling of the rotor earth fault detection system

Before dismantling the following must be done:
1. The machine must be completely stopped, dead, disconnected and grounded before
dismantling the rotor earth fault detection system and PMG.
Dismantling the rear end cover.

Remove the cable from the cable tray (if needed loosen the cable from the junction box or the
rear end). See Figure 2-1 on page 4.
Cable tray
Figure 2-1
3BSM901594, Rev. - EN
3BSM901594 4
Synchronous machine
Remove the rotor earth fault antenna in accordance with Figure 2-2 on page 5. Be careful not to
damage the rotor earth fault unit. If needed loosen the cable (from the junction box) to be able to
remove the antenna safely.
Rotor earth fault antenna
Cover drum
Figure 2-2
Loosen the bolts and remove both halves of the internal PMG protective cover plates. See
Keyphasor
Figure 2-3
3BSM901594, Rev. - EN
3BSM901594 5
Synchronous machine
Dismantling the PMG cover drum and then lift the cover drum away, by using a crane. Be
careful during the disassembly and when the cover drum is lifted away, in order not to damage
the keyphasor.
2.2 Dismantling of PMG stator

Remove the PMG stator cables from the terminal block. See Figure 2-4 on page 6.
AMS.-66
Figure 2-4
Place a sheet of stiff paper or plastic in the airgap (around PMG rotor), as shown in Figure 2-5
on page 6.
Stiff paper
3BSM901594, Rev. - EN
AMS-24
Figure 2-5
3BSM901594 6
Synchronous machine
Attach lifting chains to the PMG stator frame, remove the bolts and the guide pins. See Figure
2-6 on page 7.
Guide pin
Figure 2-6
Lift the PMG stator frame, carefully with the crane, axially away from the generator.
Note and take care of the guide pinsmotor.
NOTE: There are very strong magnetic forces between the PMG rotor and stator. Be
extremely careful when moving the PMG stator frame to avoid damage to
components due to magnetic forces. Remove your own wrist watch, credit cards
and digital equipment before working around those strong magnetic forces.
3BSM901594, Rev. - EN
3BSM901594 7
Synchronous machine
Now you are ready for changing diodes or thyristors as described in document “Replacement of
diodes and thyristors”, Figure 2-7 on page 8
AMS-33
Figure 2-7
3BSM901594, Rev. - EN
3BSM901594 8
Synchronous machine
2.3 Assembly of PMG stator

1. Be extremly careful when moving the PMG stator frame to avoid damage to components
due to magnetic forces.
2. Remove your wrist watch, credit cards and other digital equipment before working around
those magnetic forces.
Before assembling the stator, make a simple protection sleeve of stiff paper or plastic.

The PMG stator frame is a heavy.
1. Use lifting equipment that is appropriate for the load, see TBA for weight.
Lift the PMG-stator with a crane and move carfully over the paper sleeve. See Figure 2-8 on
page 9.
Protection sleeve
AMS-24
Figure 2-8
Be sure that the guide pins fit into the holes in the exciter stator .
3BSM901594, Rev. - EN
While the stator is suspended, insert all the bolts including washers and tightening the lightly.
3BSM901594 9
Synchronous machine
Check the air gap between rotor and stator, see Figure 2-9 on page 10.§
AMS-51
Figure 2-9
The air gap between rotor and stator is approx. 2.0 mm.
Adjust the air gap with the two adjusting bolts, which are placed on the stator frames lower feet
according to Figure 2-10 on page 10
Adjusting bolt
AMS-52
Figure 2-10
3BSM901594, Rev. - EN
3BSM901594 10
Synchronous machine
When an acceptable air gap is obtained, tighten the bolts, see Figure 2-11 on page 11, place
feeler guages between the stator and rotor with the desired thickness at 9 o’clock, 3 o’clock and
12 o’clock position to check that the air gap is still correct.
Guide pin
Figure 2-11
Remove the feeler guages. Check the air gap with a feeler in a final check around the periphery.
The air gap (tolerance) must not exceed 0.25mm.
If the tolerance between 3 and 9 o’clock or between 6 and 12 o’clock exceeds 0.25 mm the
bolts must be loosened and carefully retightened. The periphery must be rechecked with
feeler guages until the required tolerance is obtained. After the tolerance is reached,
redrill the guide pin holes.
Insert the cylindrical guide pins in the frames feet, see Figure 2-12 on page 11.
AMS-53
Figure 2-12
3BSM901594, Rev. - EN
3BSM901594 11
Synchronous machine
Connect the wires from the PMG stator to the terminal as shown in Figure 2-13 on page 12.
AMS-66
Figure 2-13
Remove the protection sleeve from the magnets.
Assemble the PMG cover drum.
2.4 Assembly of telemetry

Reassembly is executed in the reverse order as described in section 2.1 on page 4.
3BSM901594, Rev. - EN
3BSM901594 12
Synchronous machine
2.5 Recommended tightening torque for bolts

NOTE: Do not use Molybdenum di-sulphide, “Molycote”.
Bolt size M8 M 10 M 12
Torque (Nm) 22.5 45 79

(lbft) 16.6 33 58
Bolt size M 16 M 20 M 24 M 30
Torque (Nm) 190 420 735 1500

(lbft) 140 300 550 1100
3BSM901594, Rev. - EN
3BSM901594 13
3BSM901594
2008-02-18
Dismantling and assembly of exciter
stator
Document No.:3BSM 005448
Contents
6DIHW\
1.1 General safety instructions .........................3
'LVPDQWOLQJDQGDVVHPEO\RIWKHH[FLWHU
VWDWRU
2.1 Dismantling of the exciter stator.................4
2.2 Assembly of exciter stator ..........................9
2.3 Recommended tightening
torque for bolts..........................................10
6\QFKURQRXVJHQHUDWRUW\SH*%$
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3BSM 005448, Rev B EN -
3BSM 005448 -ii

6\QFKURQRXVPDFKLQH
6DIHW\
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specifications.
followed.
3BSM 005448, Rev B EN -
3BSM 005448 3
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1. The machine must be completely stopped, dead, diconnected and grounded before
dismatling the exciter stator.
Remove all external cables from the junction boxes on exciter stator housing. Loosen the bolts
which attache the exciter stator housing, see Figure 2-1 on page 4.
/RRVHQWKHEROWV
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3BSM 005448, Rev B EN -
3BSM 005448 4
6\QFKURQRXVPDFKLQH
:$51,1*+HDY\OLIW
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Lift carefully away the exciter stator housing, see Figure 2-2 on page 5.
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3BSM 005448, Rev B EN -
3BSM 005448 5
6\QFKURQRXVPDFKLQH
Remove the bolts of the inner cover plates between generator housing and the exciter stator, see
$06
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Remove the four bolts (two on each side) which attached the exciter stator, according to Figure
2-4 on page 6 and Figure 2-5 on page 7.
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3BSM 005448, Rev B EN -
3BSM 005448 6
6\QFKURQRXVPDFKLQH
$06
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Remove the bolts and the guide pins from the exciter stator footplates, see Figure 2-6 on page 7.
5HPRYHEROWVDQGJXLGHSLQV
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3BSM 005448, Rev B EN -
3BSM 005448 7
6\QFKURQRXVPDFKLQH
Remove the space heater before lifting away the exciter stator, to be sure not to destroy the
space heater.
:$51,1*+HDY\OLIW
7KHH[FLWHUVWDWRULVDYHU\KHDY\XQLW
Attach lifting chains to the fore and rear exciter stator flange, see Figure 2-7 on page 8, and
carefully lift the unit away to not damage the exciter rotor.
$06
)LJXUH
Each set of shims must be held together, marked and stored so that they are returned to the same
side when ressembling the exciter stator.
3BSM 005448, Rev B EN -
3BSM 005448 8
6\QFKURQRXVPDFKLQH
$VVHPEO\RIH[FLWHUVWDWRU
Assemble the exciter stator in reverse order as described in section 2.1
Carefully lift the exciter stator and slide the stator axially and very carefully over the exciter
rotor.
Place the same shims under the foot plates of the stator flange and behind the stator flange.
Replace the guide pins and the bolts.
Check the air gap.
Check that the sealing has not been damaged, if necessary replace them.
Assemble the inner cover plates between the machine housing and the exciter stator.
Assemble the exciter stator cover.
Assemble all external cables.
3BSM 005448, Rev. B EN -
3BSM 005448 9
6\QFKURQRXVPDFKLQH
5HFRPPHQGHGWLJKWHQLQJWRUTXHIRUEROWV
%ROWVL]H 0 0 0
7RUTXH (Nm) 22.5 45 79

(lbft) 16.6 33 58
%ROWVL]H 0 0 0 0
7RUTXH (Nm) 190 420 735 1500

(lbft) 140 300 550 1100
3BSM 005448, Rev. B EN -
3BSM 005448 10
3BSM 005448
2003-01-15
Dismantling and assembly of
bearing
Document No.: 3BSM 005443
Contents
6DIHW\
1.1 General safety instructions .........................3
'LVPDQWOLQJDQGDVVHPEO\RIEHDULQJ
2.1 Dismantling of bearing ...............................4
2.2 Assembly of bearings ...............................12
2.3 Recommended tightening torque for bolts in
bearing ......................................................23
6\QFKURQRXVPDFKLQH
127,&(

3BSM 005443, Rev. B EN -
3BSM 005443 ii
6\QFKURQRXVPDFKLQH
6DIHW\
6DIHW\
specifications.
followed.
3BSM 005443, Rev. B EN -
3BSM 005443 3
6\QFKURQRXVPDFKLQH
'LVPDQWOLQJRIEHDULQJ
:$51,1*5LVNRISHUVRQDOLQMXU\
%HIRUHGLVPDQWOLQJWKHIROORZLQJPXVWEHGRQH
1. The machine must be completely stopped, dead, disconnected and grounded before
dismantling the machine.
Before starting the dismantling of the bearing, rotate the rotor so that the poles are at 90 degrees
to the vertical.
Remove the upper half of the bearing support.
Disconnect the Bentley Nevada cable inside the protective housing on the bearing and remove
the Bentley Nevada probes. Remove the flexible protective tube between the Bentley Nevada
body housing and the generator end plate.
Loosen all cables from the cable brackets.
Loosen the cable from the vibration detector and remove the vibration probes.
If lower half of the bearing shell will be removed from the bearing housing, the temperature
probe has to be dismantled from the bearing housing.
7KHWHPSHUDWXUHSUREHLVDSDUWRIERWKWKHEHDULQJVKHOODQGWKHEHDULQJKRXVLQJ DQG
KDVWREHUHPRYHGLIWKHEHDULQJVKHOOZLOOEHPRYHGIURPLWVSRVLWLRQ
Remove the bolts in the upper half of the bearing housing, see Figure 2-1 on page 4, Figure 2-2
on page 5 and Figure 2-3 on page 6.
3BSM 005443, Rev. B EN -
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3BSM 005443 4
6\QFKURQRXVPDFKLQH
7L
7LJKWHQLQJFRYHU
$06

)LJXUH
3BSM 005443, Rev. B EN -
3BSM 005443 5
6\QFKURQRXVPDFKLQH
$LUORFNVHDO
$06
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Carefully lift upper half of the bearing housing away. see Figure 2-4 on page 6
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3BSM 005443, Rev. B EN -
3BSM 005443 6
6\QFKURQRXVPDFKLQH
Remove the springs on each bearing seal and remove the bearing seal, see Figure 2-5 on page 7.
$06
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Remove the bolts from the upper half of the bearing half and disconnect the earthing cable, see
Figure 2-6 on page 7 and Figure 2-7 on page 8.
$06
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3BSM 005443, Rev. B EN -
3BSM 005443 7
6\QFKURQRXVPDFKLQH
(DUWKLQJFDEOH
$06
)LJXUH
Insert lifting eyes and carefully lift the upper bearing half away, see Figure 2-8 on page 8.
$06
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3BSM 005443, Rev. B EN -
3BSM 005443 8
6\QFKURQRXVPDFKLQH
Loosen the bolts holding together the oil ring and remove them, (the oil ring is made of brass in
two halves, held together with two bolts and four cylindrical pins) see Figure 2-9 on page 9.
$06
)LJXUH
'LVPDQWOLQJRIWKHORZHUKDOIRIWKHEHDULQJVKHOO
Place a magnetic foot with a dial indicator so that the indicator can measure a vertical
movement (lift) of the rotor as shown in Figure 2-10 on page 9.
3BSM 005443, Rev. B EN -
$06
)LJXUH
Place a hydraulic jack (20 ton lifting capacity) underneath the rotor shaft as shown in Figure
2-11 on page 10 and lift the rotor 0.3-0.4 mm.
3BSM 005443 9
6\QFKURQRXVPDFKLQH
:$51,1*&RPSRQHQWGDPDJH
'RQRWOLIWRUORZHUVKDIWPRUHWKDQWKHDERYHVWDWHGWROHUDQFHRWKHUZLVH\RXFDQGDPDJH
WKHEHDULQJDWWKHRWKHUVLGHRIWKHPDFKLQH

$06
)LJXUH
Place two distance element in the air gap between the rotor poles and the stator. Attach a lifting
eye into the lower half of the bearing shell as shown in Figure 2-12 on page 10, and draw the
assembly toward you so that is slides around the journal.
$06
)LJXUH
3BSM 005443, Rev. B EN -
3BSM 005443 10
6\QFKURQRXVPDFKLQH
Insert lifting eyes as shown in Figure 2-13 on page 11 and carefully lift lower bearing shell
away.
$06
)LJXUH
Store both halves of the bearing shell in a very clean place. It is strictly forbidden to store metal
chips and other metalic components together with the bearings.
127( 0DNHVXUHWKDWWKHEHDULQJKDOYHVDUHVWRUHGWRJHWKHUDQGWKDWWKH\FDQQRWEH
FRQIXVHGZLWKRWKHUFRPSRQHQWVZKHQERWKEHDULQJ 'HQGDQG1HQG DUHVWRUHG
WRJHWKHU7KHEHDULQJKDOYHVDUHPDUNHGZLWKLGHQWLW\QXPEHUVWRDYRLGLQFRUUHFW
DVVHPEO\ZKLFKFRXOGFDXVHVHULRXVSUREOHPV
127( )RUFKDQJHRIEHDULQJVKHOORUEHDULQJVHDOVUHPRYHRQO\RQHEHDULQJDWDWLPH
'RQRWOLIWRUORZHUWKHURWRUPRUHWKDQPPRWKHUZLVHGDPDJHWRWKH
EHDULQJFDQRFFXURQWKHRWKHUVLGHRIWKHPDFKLQH
127( )RUUHPRYDORIWKHURWRUWDNHDZD\WKHXSSHUSDUWRIERWKEHDULQJKRXVLQJDQG
VKHOOVEHIRUHOLIWLQJWKHURWRUDQGEORFNLQJLWXSE\SODFLQJWKHURWRURQWRZRRGHQ
VKLPVSODFHGLQWKHDLUJDSEHWZHHQVWDWRUDQGURWRU
3BSM 005443, Rev. B EN -
3BSM 005443 11
6\QFKURQRXVPDFKLQH
$VVHPEO\RIEHDULQJV
Inspect both the upper and lower bearing shell very carefully for damage, metal chips and
impurities.The inspection is to be made by eye and by using your hand, feeling after damage.
127( ,IERWKEHDULQJVKDYHEHHQUHPRYHGPDNHVXUHWKDWWKHPDWFKLQJEHDULQJVKHOOV
DQGEHDULQJKRXVLQJVZKLFKDUHVWDPSHGZLWKLGHQWLW\QXPEHUVDUHUHDVVHPEOHG
7KHFRPSRQHQWVKDYHEHHQPDFKLQHGWRJHWKHUDQGPXVWEHPDWFKHGIRU
UHDVVHPEO\
&KHFNWKDWWKHEHDULQJKRXVLQJVDUHDEVROXWHO\FOHDQDQGIUHHIURPIRUHLJQPDWWHU
Basically, reassembly is executed in the reverse order as described in section 2.1.
The hydraulic jack is still underneath the rotor shaft as described in section 2.1, Figure 2-11 on
page 10 and use a dial indicator to measure a vertical movement (lift) of the rotor.
Apply a thin coat of oil to components which are to be assembled.
3BSM 005443, Rev. B EN -
3BSM 005443 12
6\QFKURQRXVPDFKLQH
Insert three lifting eyes in the lower bearing shell and lift the shell over and onto the rotor shaft.
Remove the two upper lifting eyes. See Figure 2-14 on page 13.
5HPRYH
$06
)LJXUH
Hold onto the upper lifting eye and allow the shell to glide around the journal until the lower
shell is inserted. See Figure 2-15 on page 13 and Figure 2-16 on page 14.
$06
)LJXUH
3BSM 005443, Rev. B EN -
3BSM 005443 13
6\QFKURQRXVPDFKLQH
$06
)LJXUH
Lower the rotor shaft carefully into the bearing shell.
Check the distance between the bearing journal and the bearing shell with a feeler guage on
front and rear end of the shell on both sides. The tolerances must be as equal as possible and the
minimum distance between bearing shell and journal must be 0.1 mm. Otherwise the rotor must
be jacked up again. Using a plastic hammer knock slightly at the horizontal joint of the bearing
shell to adjust the spherical position of the bearing. Repeat until an acceptable tolerance is
obtained.
Assemble the oil ring. Apply “Loctite” to the bolts (the oil ring is held together by two bolts and
four cylindrical pins) and tighten. See Figure 2-17 on page 14.
3BSM 005443, Rev. B EN -
$06
)LJXUH
3BSM 005443 14
6\QFKURQRXVPDFKLQH
Lift the upper bearing shell into position as shown in Figure 2-18 on page 15.
$06
)LJXUH
Connect the earth cable, se Figure 2-19 on page 15.
(DUWKFDEOH
$06
)LJXUH
3BSM 005443, Rev. B EN -
3BSM 005443 15
6\QFKURQRXVPDFKLQH
Insert the bolts and tighten the bolts with a torque wrench. See Figure 2-20 on page 16.
$06
)LJXUH
Assemble the fore and rear bearing seal and the sealing placed inside the tightening cover. See
Figure 2-21 on page 16, Figure 2-24 on page 18 and Figure 2-25 on page 18.
5HDUEHDULQJVHDO
)RUHEHDULQJVHDO
$06
)LJXUH
3BSM 005443, Rev. B EN -
3BSM 005443 16
6\QFKURQRXVPDFKLQH
&$87,218VHRIVHDOLQJFRPSRXQG
)ROORZWKHVDIHW\SUHFDXWLRQVDQGSURFHGXUHVRIWKHPDQXIDFWXUHU
Apply a thin coat of “Curil-T” sealing compound in the slot for the bearing seal, according to
)LJXU
Apply a thin coat of “Curil-T” sealing compound on the bearing seal, according to Figure 2-23
on page 17.
Note: Not on the horisontal joint
)LJXU
3BSM 005443, Rev. B EN -
3BSM 005443 17
6\QFKURQRXVPDFKLQH
6HDOLQJLQWKHWLJKWHQLQJFRYHU
$06
)LJXUH
$06
)LJXUH
The fore and rear bearing seal must be assemblied so that the axial oil drain hole is located at the
6 o’clock position, turned into the bearing and the radial guide pin (roll pin) fits into the upper
half of the bearing housing at the 12 o’clock position (the guide pin prevent rotation of the
bearing seal).
3BSM 005443, Rev. B EN -
3BSM 005443 18
6\QFKURQRXVPDFKLQH
A guide pin is placed on the upper half of the sealing (inside the tightening cover) which should
fit with the slot in the tightening cover (the guide pin prevent rotation of the sealing). See Figure
2-26 on page 19.
$06
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Clean the upper part of the bearing housing and apply a thin coat of oil to the spherical bearing
seat.
&$87,218VHRIVHDOLQJFRPSRXQG
)ROORZWKHVDIHW\SUHFDXWLRQVDQGSURFHGXUHVRIWKHPDQXIDFWXUHU
Clean the horizontal joint of the upper bearing housing carefully and apply a thin coat of
“Curil-T” sealing compound.
3BSM 005443, Rev. B EN -
3BSM 005443 19
6\QFKURQRXVPDFKLQH
Lift the upper bearing half into place as shown in Figure 2-27 on page 20.
6HDOLQJFRPSRXQG
$06
)LJXUH
Tighten the bolts with a torque wrench, see Figure 2-28 on page 20, Figure 2-29 on page 21,
and Figure 2-30 on page 21.
$06
)LJXUH
3BSM 005443, Rev. B EN -
3BSM 005443 20
6\QFKURQRXVPDFKLQH
$06
)LJXUH
Check the radiall clearance between the shaft and the sealing in the airlock cover. The distance
between the shaft and the sealing must be at 12 oćlock 0.55 mm and at 6 oćlock 0.35 and at 3
and 9 oćlock as equal as possible. Rechecked with a feeler guage until required distance is
obtained.
$LUORFNFRYHU
$06
)LJXUH
3BSM 005443, Rev. B EN -
3BSM 005443 21
6\QFKURQRXVPDFKLQH
Check the bearing insulation by megging as shown in Figure 2-31 on page 22 and Figure 2-32
on page 22. Connect the earth cable after megging.
$06
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&RQQHFWWKHHDUWK
FDEOHDIWHUPHJJLQJ
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The insulation resistance is acceptable if the value is higher then 1 Mohm.
3BSM 005443, Rev. B EN -
3BSM 005443 22
6\QFKURQRXVPDFKLQH
5HFRPPHQGHGWLJKWHQLQJWRUTXHIRUEROWVLQEHDULQJ
Recommended tightening torque for bolts, slightly coated with oil.
%HDULQJVL]H ' ' ' '

6L]H7RUTXH ' 7RUTXH ' 7RUTXH ' 7RUTXH
Bearing housing M16 170 Nm M20 330 Nm M24 570 Nm
125 lbft 243 lbft 420 lbft
Tightening cover M6 5-7 Nm M8 10-15 Nm M8 10-15 Nm
(hand-tight) 3.7-5.2lftb 7.4-11 lftb 7.4-11 lftb
Bearing shell M8 20 Nm M12 69 Nm M12 69 Nm
Air lock cover M6 5-7 Nm M8 10-15 Nm M8 10-15 Nm
3.7-5.2lftb 7.4-11 lftb 7.4-11 lftb
Oil ring M4 1.4 Nm M5 2.7 Nm M5 2.7 Nm
1 lftb 2 lftb 2 lftb
3BSM 005443, Rev. B EN -
3BSM 005443 23
3BSM 005443
2001-09-13
Service & Repair Synchronous machine
Instruction for removal of
rotor on site
(AMS 710, 800, 900)
Document No.: 3BSM 009019
Contents
1 - Safety
1.1 General safety instructions ......................... 3
2 - Instruction for removal of rotor on site.

2.1 Overhaul of machines according to Level 4
inspection in the manual............................. 4
2.2 Planned work.............................................. 4
2.4 Assembly of main rotor............................ 11
2.5 Recommended tightening torque for
bolts .......................................................... 13
Synchronous motor, type GBA
Removal removal
NOTICE
The information in this document is subject to change without notice and should not be construed as a commitment by ABB
Industrial Systems AB. ABB Industrial Systems AB assumes no responsibility for any errors that may appear in this document.
This document and parts thereof must not be reproduced or copied without ABB Industrial Systems AB’s written permission,
and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.

3BSM 009019, Rev. A EN -
3BSM 009019 ii
Synchronous machine
Safety
1 Safety
1.1 General safety instructions

specifications.
followed.
3BSM 009019, Rev. A EN -
3BSM 009019 3
Synchronous machine
Rotor removal
2 Instruction for removal of rotor on site.
2.1 Overhaul of machines according to Level 4 inspection in the manual
Preparations

Make sure that all equipment is in good condition and appropriate for the load before
starting the procedure.
Site PPE requirements.

• Hi Viz Jacket
• Safety Helmet
• Safety Glasses
• Safety Boots
2.2 Planned work

Remove the cooler top, covers, bearings, main rotor and perform level 4 inspection.
Dismantling, assembling and inspections including measurements in accordance with the order
specific manual for the machine.
3BSM 009019, Rev. A EN -
3BSM 009019 4
Synchronous machine
Rotor removal
2.3 Removal of main rotor

When the rotor is coming out of the stator and is supported for bolting on a new
extension piece, make sure to place an external support under the exciter end. The
centre of gravity is otherwise outside the support and the rotor will tip, possibly
endangering personnel.
Sliding plate D
Sliding support plate
Front support
Sliding plate ND
Figure 2-1
NOTE: It is strongly recommended that rotor removal and reassembly should be

performed by professional service or commissionining engineers authorised by
ABB.
1. Ensure that a valid permit to work is applicable and all members of the working party are
familiar with the work method statement, the specific maintenance procedures and test
required.
2. Ensure before working on any electrical equipment, general electrical safety precautions
are to be taken and local regulation are to be respected, according to instructions of the
customer personal in charge of security, in order to prevent personnel accidents. See users
manual, Chapter 7.
3BSM 009019, Rev. A EN -
3. Ensure before start of work that the machine is disconnected from the high voltage net and
that the circuit breaker is locked in the open position so it not accidentally (or otherwise)
3BSM 009019 5
Synchronous machine
Rotor removal
can be closed during work and measurements. Ensure that the machine is grounded. See
users manual, Chapter 5.
4. Before use inspect the installed lifting equipment and ensure that all lifting equipments
have current test certificates.
5. Disconnect the machine shaft from all the driven object. The rotor pole position should be
3, 6, 9 and 12 o’clock.
6. Remove the inspection covers on ND- and D-side. Remove the cooler top by the crane.
7. (If PMG), remove the PMG stator by the truck and in accordance with the manual.
8. Remove the exciter stator by the truck and in accordance with the manual.
9. Remove the pipes for oil, temperature probes etc from the bearing in accordance with the
manual.
10. Assembly the draw plate to the shaft end on ND-end.
11. Erect the mobile/overhead crane on the ND-end side for lifting and removing of the rotor.
See Figure 2-2 on page 6.
Front support
Figure 2-2
12. Dismantle the upper half of the ND- and D-end bearing in accordance with the manual.
13. Place the lift jack underneath the shaft on D-end side.
14. Lift the rotor about 5 mm.
15. Dismantle the lower part of the ND-end bearing and the end shield.
3BSM 009019, Rev. A EN -
16. Mount the front support of the sliding tool on the ND-end of the machine housing.
3BSM 009019 6
Synchronous machine
Rotor removal
Sliding support plate
Figure 2-3
17. Place the sliding support plate into the air gap between the rotor and stator. Extreme care
should be taken when inserting the tool not to damage the stator core and winding. See
Figure 2-2 on page 6 and Figure 2-3 on page 7.
18. Bolt the sliding support plate to the front support.
19. Place the two sliding plates into the air gap, one at ND-end and one at D-end.
Towing equipment Towing eqiupment

Max 5kN
Max 5kN
Figure 2-4
20. Apply the towing equipment on D-end and ND-end, use tackle blocks/chain hoists
(optional equipment) and slings (optional equipment). See Figure 2-4 on page 7.
D-end - shall be mounted somewhere on the gearbox/steam turbine, on a hook in the
wall or something else and around the shaft end, and shall be used as
counterstay to prevent to much movement during the removal of the rotor.
ND-end - shall be mounted on a hook in the wall or somewhere else and to the draw plate
mounted on the shaft, and shall be used to draw the rotor out of the stator.
3BSM 009019, Rev. A EN -
21. Remove the lower half of the D-end bearing and end shield in accordance with the manual.
3BSM 009019 7
Synchronous machine
Rotor removal
22. Lower the rotor so that it rests on the sliding tool. See Figure 2-5 on page 8.
Figure 2-5
23. Remove the lift jack on D-end side.
24. Gently pull the rotor towards to the ND-side and at same time loose on D-side until the
centre of the rotor is well outside the machine housing.
25. Support underneath the shaft on the ND-end by hard wood. See Figure 2-6 on page 8.
Figure 2-6
3BSM 009019, Rev. A EN -
3BSM 009019 8
Synchronous machine
Rotor removal
26. Move the slings to be around the rotor body and move carefully towards the ND-side. Be
sure that the rotor is in balance before moving so the rotor not will destroy the stator coil
ends. Move until the rotor is free to lift away. See Figure 2-7 on page 9
Figure 2-7
27. Dismantle the towing equipment.
28. Lay down the rotor on the cradle. See Figure 2-8 on page 9.
Cradle
Figure 2-8
29. Perform the inspection Level 4 in accordance with the manual.
3BSM 009019, Rev. A EN -
3BSM 009019 9
Synchronous machine
Rotor removal
Store the rotor on solid supports and high enough so that the exciter not will be destroyed.
Protect the rotor with a tapaulin.
Store both halves of the bearing shells in a very clean place- It is strictly forbidden to store
metal chips and other metallic compontent together with the bearings.
Make sure that the bearing halves are stored toghether and that they cannot be confused
with other components when both bearings (D-side and ND-side) are store together. The
bearing halves are marked with identity numers to avoid incorrect assembly which could
cause serious problems.
3BSM 009019, Rev. A EN -
3BSM 009019 10
Synchronous machine
Rotor removal
2.4 Assembly of main rotor

If the sliding tool have been removed, mount them back according item 1-4.
1. Mount the front support of the sliding tool on the ND-end of the machine housing.
2. Place the special sliding tool into the stator winding. Extreme care should be taken when
inserting the tool not to damage the stator core and winding.
3. Bolt the sliding support plate to the front support.
4. Place the two sliding plates into the stator, one at ND-end and one at D-end.
5. Lift the rotor in position as in Figure 2-9 on page 11 and the rotor pole possition should be
3,6,9 and 12 o’clock. Be sure that the rotor is in balance when moving the rotor into the
stator so not the rotor will not destroy the stator winding. .
Figure 2-9
6. Put a support underneath the shaft on the ND-end by hard wood.
7. Move the slings from the rotor body to the shaft end (ND-side) according to Figure 2-10
on page 11.
Towing eqiupment
Towing eqiupment
Figure 2-10
8. Apply the towing equipment on D-end and ND-end, use tackle blocks/chain hoists
3BSM 009019, Rev. A EN -
(optional equipment) and slings (optional equipment). See Figure 2-10 on page 11.
D-end - shall be mounted somewhere on the gearbox/steam turbine, on a hook in the
3BSM 009019 11
Synchronous machine
Rotor removal
wall or something else and around the shaft end, and shall be used to draw the
rotor into the stator.
ND-end - shall be mounted on a hook in the wall or somewhere else and to the draw plate
mounted on the shaft, and shall be used as counterstay to prevent to much
movement during assembling of the rotor.
9. Gently pull the rotor towards to the D-side and at same time loose on ND-end until the
rotor is in place in the stator in same position as before dismantling.
10. Place a lift jack underneath the shaft on D-end side. Figure 2-11 on page 12
Figure 2-11
11. Lift the rotor, on D-end, about 0.5mm with the lifting jack.
12. Assembly the lower half of the D-end bearing and end shield in accordance with the
manual.
13. Remove the towing equipments.
14. Remove the two sliding plates from the air gap.
15. Loosen the bolts for the sliding support plate from the front support.
16. Remove the sliding support plate.
17. Reassembly the lower part of the ND-end bearing and the end shield.
18. Lower the rotor down into the bearing.
19. Remove the lifting jack from D-side.
20. Remove the lifting slings.
21. Reassembly the upperhalf of the ND-end and D-end bearing accordance with the user’s
manual.
22. Reassembly the pipes for oil, temperature probes, etc from the bearing in accordings with
the user’s manual.
23. Reassembly the exciter stator by the truck and in accordance with the manual.
24. (If PMG) Reassembly the PMG stator by the truck in accordance with the manual.
25. Reassembly the inspection covers on ND-side and D-side.
26. Reassembly the cooler top.
27. Connect the machine shaft to the driven/driving object.
28. Clean and clear site working area of all tools and equipment.
3BSM 009019, Rev. A EN -
3BSM 009019 12
Synchronous machine
Rotor removal
2.5 Recommended tightening torque for bolts

NOTE: Do not use Molybdenum di-sulphide, “Molycote”.
Bolt size M8 M 10 M 12
Torque (Nm) 22.5 45 79

(lbft) 16.6 33 58
Bolt size M 16 M 20 M 24 M 30
Torque (Nm) 190 420 735 1500

(lbft) 140 300 550 1100
3BSM 009019, Rev. A EN -
3BSM 009019 13
3BSM 009019
2005-06-01

ABB AMS 800SF Generator Installation Manual

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ABB AMS 800SF Generator Installation Manual

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Installation and Synchronous generator,

maintenance type AMS 800SF

©Copyright 2001 ABB. All rights reserved.

Chapter 2 - Transport, Storage and Preparation for erection

Chapter 4 - Mechanical and electrical installation

4.1.2 Connection of oil pipes ............................................................................ 23

4.2 Electrical installation ................................................................................................ 24

7.3.8 Cooling system ........................................................................................ 53

7.3.10 Purge system ............................................................................................ 53

Chapter 8 - Disposal and Recycling

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1.1 General information

1.3 Site conditions

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1.6 Manual system and related documents

Project: TUNU 11S

Users Manual ABB AB, Machines

General ABB AB, Machines

Drawings for the generator

Machine part list

Installation & Maintenance manual

Main terminal box

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Chapter 2 Transport, Storage and Preparation for erection

2.1 Transport and unpacking

2.1.1 Protective measures prior to transport

2.1.2 Check upon arrival

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2.1.3 Transport anchor points

CAUTION - Risk of component damage

Optional anchoring point

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2.1.4 Transport anchor points

CAUTION - Risk of component damage

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2.1.5 Lifting of crated equipment

WARNING - Heavy lift

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2.1.7 Lifting of equipment

WARNING - Heavy Lift

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WARNING - Heavy Lift

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WARNING - Heavy lift

2.2 Storage (this generator is prepared for long term storage)

2.2.1 Short term storage of crated generator

Storage < 9 month

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2.2.2 Long term storage of crated generator

Storage > 9 month

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2.2.3 Short term storage of uncrated generator

Storage < 9 month

2.2.4 Long term storage of uncrated generator

Storage > 9 month

Before commissioning the following items should be carried out:

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2.3 Preparation for erection

2.3.1 Check of foundation

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2.3.2 Vertical and horizontal positioning

CAUTION - Risk of personal injury

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