Generator AvK

Contents
1 General Notes and Instructions

Safety precautions
Check list
Maintenance schedule
Customer contact list & Complaint report
2 Drawings
Dimension drawing alternator AZ 20666
Rotor drawing 83602
Lifting of Generator T67M00300XY
3 Circuit Diagram
Circuit diagram K 850.3.135
Legend to circuit diagram K 850.3.135
4 Operating Instructions
Three-phase synchronous electrical machines series DIG 110...191
Enclosure to operating instructions
5 Regulator Descriptions
Voltage regulator Unitrol 1000
6 Rotor mounting/dismounting description

Rotor mounting/dismounting
7 Bearings
Installation and Operation Instructions ZF bearings
Recommendation for synthetic lubricants for sleeve bearings
(Klüber Summit SH 46)
8 Spare Parts
Drawings 0.2.0, 1.2.2, 3.0.0.1ms, 4.0.0oRT, 6.0obi
9 Technical Data
Technical Data
Data sheet for PT 100
Information to explosion protection device
Test report 8429187A001+B001+C001+D001
Klüber recommendation worldwide
Wärtsilä Finland Oy - Power Plants 07/2008

Your order: 4500666113
Your project: Maona (Bangladesh)
AvK Order no. 8429187A001+B001+C001+D001
General Notes
General Notes
Safety Precautions
Read this advice as well as additional parts can be found in the
the operating instructions documentation.
supplied prior to
commissioning or storage of The documentation, including the
the generator. operating instructions, are part of the
Any works on the generator have to be machine and have to be passed on to the
performed by qualified and trained next user in case the generator is sold or
personnel only. moved.
Any person, working on the generator
has to read and understand these 1.2 Liability and guarantee
operating instructions.
All statements and advice in the operating
instructions are made under consideration
1. General Notes of our present knowledge and experience.
1.1 Important notes for users The technical information

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

close to the generator and have to be changes on the generator are not allowed
available for the personnel at any time. for reasons of safety and will exclude any
liability of AvK for resulting damages. If
Please take notice of the safety transformers supplied by the customer
precautions in chapter 2. Further safety shall be installed in the terminal box, AvK
precautions are mentioned in the has to be consulted first.
respective chapters.
The preceding notes do not extend the
The order related data of the generator as terms of liability and guarantee of the
well as the operating instructions for general delivery terms of AvK.
Cummins Generator Technologies Germany GmbH Page 2

POD-intro-AvK-eng-safetyprecautions.doc
Manufacturer's Address
Follow all warnings and
AvK Deutschland GmbH & Co. KG advice and act very carefully
Bunsenstraße 17 in these cases. Inform all
D-85053 Ingolstadt persons working on the
generator about all work-safety
Phone (+49) (0)841 / 792-0 regulations.
FAX (+49) (0)841 / 792-250
All rights reserved. Reprints 2.2 Signs on the generator

or copies - even extracts -
need the permission of AvK. At particular dangerous points on the
generator you will find safety notes. To
2. Safety Precautions avoid damages to persons or values these
safety notes have to be followed very
During transportation, installation, strictly.
commissioning and maintenance, certain
works might have to be performed on the
generator, e.g. on feet support, shaft end, Achtung!
bearings, terminal box, etc. The working Betriebsanleitung
area and area of danger includes the Im Klemmenkasten!
surroundings of the generator and the Vor Inbetriebnahme unbedingt lesen.
prime mover.
During normal operation, the working area Caution!
should be limited to the operating and Operating instructions are inside the
monitoring devices of the switchboard. terminal box. These must be read prior to
commissioning.
Despite taking into consideration all safety
precautions, the generator may be a The documents for the generator are in
source of danger, electrically and the terminal box
mechanically. To avoid damages to
persons and values, all safety precautions
have strictly to be followed. Transportsicherungen.
Vor Inbetriebnahme entfernen
Beside all safety notes in the operating
instruction the local safety precautions and Transport Safety Devices
rules for the prevention of accidents have Remove prior to commissioning.
to be followed. During transportation the rotor is secured
against shifting. The transport safety
2.1 Description of symbols and advice devices have to be removed before
commissioning.
The following symbols are used in the
instructions to highlight particular points
and actions: Maschine nicht betriebsfähig!
Machine out of order

Warning! Life in danger!
This sign is mounted when the installation

of transformers in the terminal box is
Danger! necessary. The transformers have to be
installed prior to commissioning. In this
case the installation manual for the
Besides these safety notes all local valid transformers is in the terminal box and in
instructions for safety and accident the enclosed documents.
prevention have to be followed.
All safety devices like covers, barriers and
E-Teile im Klemmenkasten protections have to be in place and must
be functioning perfectly at all times.
Spare Parts are inside
It is not permitted to operate
the generator with damaged
Spare parts that are delivered with the safety devices!
generator are in the terminal box. The
spare parts have to be removed.
2.3 Safety at site
ABSTANDSMAß-PROTOKOLL For operating the electrical machine the

AM GLEICHRICHTERTÄGER responsibilities have to be determined
clearly and kept, so that no unclear
Mounting-distance test-report is inside situation regarding safety may occur.
The generator must only be operated
when it is in an excellent state and
For the alignment of single bearing according to the design data. Any change
machines it is important to keep the that reduces the safety has to be reported
mounting distance between rotor and to the responsible person immediately.
stator on the NDE of the generator.
The respective report can be found on the Modifications on the
rectifier carrier at the NDE of the machine are only allowed in
generator. agreement with AvK and
these are to be performed
under supervision of qualified
ACHTUNG! personnel.
Vor Inbetriebnahme Öl einfüllen.
Menge und Qualität laut Beschreibung The way to the operating and monitoring
devices has to be free and must not be
Caution! obstructed by any objects.
Fill in oil prior to commissioning!
Please refer to operating instructions of Prior to commissioning and
the sleeve bearing manufacturer for during maintenance works, all
amount and quality. persons in the danger area
have to be warned. They must
Generators with sleeve bearings need oil be ordered to leave the area.
to be re-filled before commissioning. The
instructions from the sleeve bearing After completion of work, the generator
manufacturer are enclosed. must be checked by qualified personnel to
ensure it is in a safe working state.
2.2 Safety Devices
2.4 Safety precautions for maintenance
Special covers are mounted to protect
against mechanical danger (e.g. rotating Maintenance should normally
parts). Protection against electrical danger only be performed when the
is provided by covers and devices against generator is out of operation
over-voltage and over-current. It is not (except for the re-lubrication
allowed to change or dismount any safety of anti-friction bearings). The prime
devices or to put them out of order. mover has to be disconnected.
Unprotected machine parts may cause After completion of the maintenance work,
severe injuries. it must be ensured that all protection and
safety devices are back in place properly.
2.5 Special Dangers

complete unit (generator and prime
The operator of the machine mover)
has to take care, that the
rules for fire protection are • For transporting the machine, the
kept and the equivalent following devices are permitted:
agents for fire extinction are available
near the machine and ready for use. - Cable and chains,
3. Shipping, Handling, Storage that comply with the local regulations,

that have a sufficient carrying capacity,
3.1 Safety precautions for transport that are in an excellent working condition
Please comply with the local It is not permitted to use

valid regulations for cables that are torn or worn.
shipments. Cables and chains may not be
knotted. Cables and chains
must not touch any sharp edges.
Warning!
Never move loads over - Lifting devices: cranes
persons! overhead cranes
• The shipment and the unloading of the • Moving the machine over rough
generator must only be performed by ground e.g. rails, by using a haulage
personnel, who are familiar with the car is not permitted. This may cause
lifting cranes and corresponding damage to the bearings and the
devices. windings. This is especially important
for the moving of the machine within
• The lifting devices have to be designed the factory.
for the weight of the generator
(Chapter 3.4). 3.2 Packaging
• Follow the shipping instructions The material used for the packing of the
(pictographs) on the cover of the generator is made of ozone-friendly
generator. material – like wood. The packaging
depends on the mode of transport used –
• The generator must only be supported surface, water or air freight.
on its feet. The support on any other When the transport time is for a longer
part is not permitted. That is why the period, then the generator will be packed
generator is delivered with a in a protective covering against dust or
transportation construction. humidity.
• For the lifting of the generator, ring 3.3 Checking for Shipping Damage
bolts are mounted on the generator
housing. We recommend checking the
generator for shipping
Ring bolts, that are mounted damages and complete
on add-on pieces like e.g. the delivery by the time of
cooler top, must not be used delivery.
to lift the whole machine!
They are only used as mounting device If there are damages on the goods (open
for these add-ons. damages) report these to the haulage
contractor at take-over. In this case, the
• The ring bolts can only be used for the receipt should only be given under
transport of the separate machine, reservation with a written statement
they are not designed to lift the regarding the estimated amount of the
damage.
If damages that were not noticeable by the
time of delivery (covered damages), are
detected later, they have to be reported
promptly to AvK, latest 6 days after receipt
of the delivery.
3.4 Unloading the generator
The unloading has to be performed in

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

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

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

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

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

generator for a longer period
of time, please contact AvK
for further information.

Cummins Generator Technologies Germany GmbH
Bunsenstraße 17
85053 Ingolstadt, Germany
Phone: +49(0)841-792-0
Fax: +49(0)841-792-250
e-mail: info@cumminsgeneratortechnologies.com
www.cumminsgeneratortechnologies.com

Dreieich Office
Benzstraße 47-49
63303 Dreieich, Germany
Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40
www.cumminsgeneratortechnolgies.com

AvK Checklist to Order No. Page 2
Customer: .............................................................
Order No.: .............................................................
Generator Type: .............................................................
Operation Hours: .............................................................
Bearing design: Roller bearing
Sleeve bearing
YES NO
Replacement of oil:
YES NO
Bearing inspection performed:
I. Electrical Inspection
Pos. 1.1 - 1.19
II. Mechanical Inspection
Pos. 2.1 - 2.20
III. Test Run
Pos. 3.1 - 3.14
IV. Maintenance Result

POD-intro-AvK-eng-checklist.doc
Environmental Conditions:
a) Location: building marine
b) Atmosperic conditions: dry high humidity

dust salt
c) Ventilation: unrestricted adequate

restricted inadequate
Operating Conditions:
a) Site duty: single parallel idle
b) Duty cycle: 24 hours daily occasionally standby

c) Load condition: inductive non linear
d) Operation: manned unmanned
Generator Conditions:
a) Dirt content: slight dust light layer dirt

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

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

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

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

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

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

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

c) Stator winding phase W against ground

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

b) Stator winding phase U against phase W

c) Stator winding phase W against phase V

1.8 Resistance measurement of stator

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

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

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

b) Insulation measurement exciter rotor

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

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

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

water

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

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

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

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

see page 11
3.14 Bearing and winding temperature after continuous

operation
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________

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

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

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

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


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

Dreieich Office
Benzstraße 47-49
Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40

Cummins Generator Technologies Germany Gmbh Page 1 of 2
Suggested Maintenance Schedule for AvK Order No.:

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

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

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

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

Cummins Generator Technologies Germany Gmbh Page 2 of 2
Suggested Maintenance Schedule for AvK Order No.:

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

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

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

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

Customer Contact List DA 7.5-1
Service and Warranty Claim Handling for AvK Alternators 1 von 2
Technical Service on-site (after warranty):

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

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

Guiseppe Cinnirella Joseph.cinnirella@newage-avkseg.com +39-(0)2-38000 ~714 ~664
Products
Norway
Sweden
All AvK Denmark
Jan Jakobsen J.Jakobsen@newage.no +47-(0)22-9744~37 ~45
Products Finland
Baltic States
Russia
North America 001-763-528-7301-6
South America
All AvK Direct: 001-763-574 ~5000 ~5082
Mexico Gary O`Malley Gary.b.omalley@newage-avkseg.com
Products Central America TOLL FREE: (1) 800 ~367-2764 ~863-9243
Canada
Australia +61-(0)2-9680 ~2299 ~1545
All AvK
New Zealand Theo Dragonas Theo.dragonas@newage-avkseg.com
Products Mobile: +61-(0)412-886643
South Pacific
All AvK +41 317 408 282
Switzerland Martin Läderach laederach_interplan@bluewin.ch +41 317 408 280
Products Mobile: +41 7920 17561
Dokumentenname:
Cummins Generator Technologies Germany GmbH Revisionsstand:
POD-intro-AvK-eng-customercontact.doc
C vom 02.05.08
Stand: C vom 02.05.08
Customer Contact List DA 7.5-1
Service and Warranty Claim Handling for AvK Alternators 2 von 2
Products Countries Contact E-mail Phone Fax

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

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

Service Manager Assistant Service Manager
Unterschrift:
Norbert Steller Emilia Sandau
Dokumentenname:
Cummins Generator Technologies Germany GmbH Revisionsstand:
POD-intro-AvK-eng-customercontact.doc
C vom 02.05.08
Stand: C vom 02.05.08
Drawings
Circuit Diagram
Seite 1 Legende zum Schaltbild Nr. Legend to Circuit Diagram No.
Page 1 K 850.3.135 K 850.3.135
B5 Spannungsregler UNITROL 1000 Automatic voltage regulator UNITROL 1000

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

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

(nicht AvK Lieferumfang) 10 A (not AvK supply) 10 A
Erstellt am: 24.11.06 Issued on: 24.11.06
AvK geprüft von: Diegeler Checked by: Diegeler
Revision Nr.: 0 Revision No.: 0
Operating Instructions
Operating instructions
Three-phase synchronous electrical machines,
Series DIG 110…191 with "COSIMAT N" voltage regulator
CONTENTS
1 Operating and maintenance instructions........................................................................ 3

1.1 Checking for damage incurred during transit................................................................ 3
1.2 Transport...................................................................................................................... 3
1.3 Storage ........................................................................................................................ 3
1.3.1 Preservation.......................................................................................................... 3
1.4 Setting up the machine ................................................................................................ 4
1.5 Cooling the machine .................................................................................................... 4
1.5.1 Coolant temperature ............................................................................................. 4
1.5.2 Direction of cooling air .......................................................................................... 4
1.5.3 Quality of cooling air ............................................................................................. 4
1.6 Dust filter...................................................................................................................... 4
1.6.1 Synthetic filter elements ........................................................................................ 4
1.6.2 Woven metal filter elements.................................................................................. 5
1.7 Preparations for starting up .......................................................................................... 5
1.7.1 Removing preservation ......................................................................................... 5
1.8 Machine drive............................................................................................................... 5
1.8.1 Belt drive............................................................................................................... 5
1.8.2 Coupling drive ....................................................................................................... 6
1.9 Aligning the machine.................................................................................................... 6
1.10 Changing direction of rotation................................................................................... 7
1.11 Electrical connections............................................................................................... 7
1.12 Starting up ................................................................................................................ 8
1.12.1 Insulation resistance ............................................................................................. 8
1.12.2 Operating speed ................................................................................................... 8
1.12.3 No-load operation ................................................................................................. 8
1.12.4 Parallel operation .................................................................................................. 8
1.12.5 Loss of remanence ............................................................................................... 9
1.13 Power factor regulation............................................................................................. 9
1.14 Interference suppression .......................................................................................... 9
1.15 Operation.................................................................................................................. 9
1.16 Maintenance............................................................................................................. 9
1.17 Bearings ................................................................................................................. 10
1.17.1 Ball and roller bearings ....................................................................................... 10
1.18 Drying out the machine........................................................................................... 12
Cummins Generator Technologies Germany GmbH page 2 to 13

POD-geno-AvK-eng-DIG110191.doc
Storage
1 Operating and maintenance in- If the machine is to be stored after trial running,
structions note the following points:
1.1 Checking for damage incurred during

transit 1.3.1 Preservation
Immediately after receiving the machine, inspect it • Complete machine

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

Setting up the machine Important:
The distance between the air inlet or outlet on
The installation site must comply with the ma-
the machine and any nearby wall must not be
chine’s enclosure rating and be sufficiently large
less than the dimension stated below, other-
for cooling and maintenance purposes. When
wise ventilation will be obstructed.
setting up the machine, make sure that:
Minimum distance (guide value):
1 x diameter of machine
• The relevant operation and maintenance
safety regulations are observed
1.4.3 Quality of cooling air
• Cooling air can enter and exit freely
To extend the service life of the machine, and in
• Exhaust gas and heated cooling air cannot be particular its windings and bearings, it is extremely
drawn in by the machine important that neither contaminated not aggres-
sive cooling air be allowed to enter it. An air filter
can be installed if requested by the customer, or
1.4 Cooling the machine can be trofitted provided sufficient space is avail-
able.
1.4.1 Coolant temperature
Unless otherwise specified, the machine is built to
run at a coolant temperature of up to 40°C and at 1.5 Dust filter
an installation height of up to 1000 meters above
If the machine is equipped with dust filters, please
mean sea level. Please refer to the machine’s
note the following points.
data plate for coolant temperature and power
rating.
• The cooling air must not exceed the tempera-
ture stated on the machine’s data plate.
Coolant temperatures higher than stated on the
machine’s data plate will result in power loss.
• At the appropriate intervals, the filters should
be checked to establish their degree of con-
Coolant temperature Max. available power
tamination with dust and dirt.
45°C 96%
50°C 92,5%
To ensure that the machine’s windings cannot
overheat as a result of blocked filters, three tem-
If the machine is ordered to run at coolant temperature sensors are provided in the stator wind-
peratures higher than 40°C, this is shown on its ing. These sensors must be connected to the
rating plate together with the alteration in power warning system.
rating.
1.5.1 Synthetic filter elements

1.4.2 Direction of cooling air
These are dry-type filters and must be cleaned at
The machine is cooled by an integral fan de- regular intervals, which depend on the amount of
pendent on the direction of rotation, mounted dust and dirt trapped by the filter. Filter elements
on the shaft. It draws cooling air through the ma- can be cleaned with compressed air, water at a
chine and expels it at the fan side. temperature not exceeding 50°C or a liquid deter-
gent, but it is often a more economical proposition
To ensure proper cooling, make sure that the to renew them.
direction of fan rotation is as indicated by the ar-
row on the machine. Comply with all relevant environmental protec-
tion and safety regulations.
If it is intended to use forced cooling, either alone
or to support the integral fan, the direction of air-
flow and rotation must be correct here too.

Woven metal filter elements If the machine was given protective treatment
following a trial run, the following measures must
These are supplied dry, that is to say not wetted
be taken:
with oil. They can either be operated dry or
sprayed with special filter oil. If the filter elements
are sprayed with oil, comply with the relevant
1.6.1 Removing preservation
environmental protection laws when cleaning
them. They can be cleaned with a high-pressure • Complete machine
cleaning unit. Additives to dislodge grease can be Check the machine’s insulation resistance. If it is
used, provided that they have been checked for below the minimum value (see Chapter 1.12.1,
compatibility with the filter material. After cleaning, Insulation resistance), the machine must be dried
dry the filter elements and if necessary spray the out. The procedure is described in Chapter 1.18.,
with fresh oil. Drying out the machine.
Comply with all relevant environmental protec- • Shaft end, flange and bright metal areas
tion and safety regulations.
Remove the protective lacquer coating with a
Regular cleaning of the filter elements is still suitable solvent. Do not rub it off with emery cloth.
needed even if the electrical machine’s windings Comply with the relevant environmental protection
are protected against overheating by built-in tem- and safety regulations.
perature sensors. Careful attention to this point
will ensure that the machine always runs cool and • Bearings
reliably.
Sleeve bearings
Dismantle and clean the sleeve bearings. The
1.6 Preparations for starting up corrosion inhibiting agent must be removed. (this
is not necessary if Tectyl 511 M was used and the
Pull the protective lacquer coating off the end of
storage period was fairly short, provided that the
the shaft and the flange, or remove it with solvent.
bearing is then lubricated with mineral oil).
Never clean it off with emery cloth. Comply with
Fill the sleeve bearings with oil as stated on the
the relevant regulations on environmental protec-
lubrication plate and in the operating instructions.
tion and safety.
There is a threaded hole on the shaft, to which a
Ball and roller bearings
puller can be attached for installing and removing
Open the bearing housing and remove the addi-
discs or couplings. Hammering is not permitted,
tional quantity of grease which was previously
as this can damage the bearings. If the machine is
added to the bearings so that only the specified
delivered with shipping brace in position, remove
amount remains in the bearing (see chapter on
it.
renewing bearings and lubrication plate).
If the machine is of single bearing design, its rotor
is delivered attached to the shaft flange and the • Cooler
housing by a steel hoop to prevent axial dis-
placement and is located in position radially be- Add water to the cooling circuit and operate it in
tween the shaft and fan housing by an angle accordance with the cooler manufacturer’s operat-
bracket. Both these transit keepers (axial and ing and maintenance instructions.
radial) must be removed.
Make quite sure that the radial transit keepers are 1.7 Machine drive
removed from the gap only after the rotor has 1.7.1 Belt drive
been centred on the drive shaft flange. Failure to
do so can result in damage to the exciter machine If the machine is driven by a belt, the machine
and the NDS (Non-drive-side) bearing. must be ordered specifically with bearings and
bearing lubrication to match the higher loadings.
In the case of machines with a steel disc coupling, Most belt-driven machines have roller bearings on
the radial transit keepers are screws in the flange the input side.
bell. They must be removed after the machine has
been aligned and its position fixed in relation to The rotor must be ordered with balancing by
the drive input. solid key, and the grooved belt pulley must be
dynamically balanced on a smooth mandrel. The
belt must run smoothly, without jerking.
Desired balancing accuracy: ≤ Q 2,5 according to tolerances and clearances included with the ma-
German VDI 2060 standard. chine. For further instructions, see the chapter on
plain bearings.
When flat-type belts or V-belts which have already On machines with a steel disc coupling, radial
been in operation for a fairly long time are re- rotor alignment is by means of centering screws
moved for maintenance purposes, they must be inserted into the centering bell. These screws also
replaced by new ones (in case of hardening). act as transit keepers in a radial direction. They
replace the pressboard inserts otherwise placed in
Important: the air gap. Alignment is checked by measuring
Belts that are tensioned too tightly can put the the distance between the outer rim of the steel
bearings at risk. For this reason, establish the disc coupling and the machined inner diameter of
correct belt tension with the belt manufacturer the centering bell.
or the plant that supplied the machine, and In the case of single-bearing machines with a
have checks carried out on site. divide DS (drive side) end shield, accuracy of
alignment is checked by measuring the air gap.
1.7.2 Coupling drive If the machine has an undivided bearing plate, a

machined end disc is installed at the drive side.
Unless expressly ordered otherwise, the rotor is The measurement is then made between the shaft
balanced with a solid key. The grooved drive ele- and the machined inner diameter of the end plate.
ments must therefore be balanced on a smooth Take three measurements in each case, at 120-
mandrel. degree intervals round the shaft. The results must
not vary by more than 0,2 mm.
The coupling must be dynamically balanced to an This will ensure a uniform air gap beneath all
accuracy of poles and the correct axial position of the rotor.
≤ Q 2,5 according to VDI 2060. Check alignment accuracy at the end of the shaft
or at the coupling.
When installing the coupling on to the shaft end, While checking, turn the coupling slowly through
make sure that no hammer-blows or shocks are 360°C, at the same time taking the readings at the
transmitted to the machine’s bearings. Always use individual dial gauges. Attach one dial gauge ra-
a suitable puller. dially and two axially, to compensate for rotor
displacement. Refer to the coupling manufac-
When pulling the coupling on, comply with its turer’s data as a guide to permissible deviations
manufacturer’s assembly instructions. Unless from true alignment.
otherwise stated by the supplier, the coupling half
can be heated up to 80°C. It can then be pushed
on to the shaft end easily. Ensure that the drive
element is securely located after tightening, and
securely clamped against the mechanical stop on
the shaft.
1.8 Aligning the machine

Precise, careful alignment of the machine ensures
that it runs with the minimum vibration, thus ex-
tending the service life of the machine and in par-
ticular of the bearings. This applies to machines
with either flexible or rigid couplings.
Even slight errors of alignment can rapidly

result in damaged bearings.
It is vital that all the feet are fully in contact. Un- Possible test method:
even under surfaces cause stresses in the bear- Slowly turn the coupling through
ings and must be compensated for by attaching 360°C and determine maximum
sheet metal strips. Once the machine is aligned deflection of the dial gauge.
correctly, secure it with dowel pins. When aligning
a machine of single bearing design, it is important M = dial gauge
to comply with the reference dimensions specified
on the dimension sheet and the drawing showing

Guide values
Shaft centre displacement Shaft tilt Coupling gap*

* Note coupling manufacturer’s data and allow for thermal expansion at the electrical machine and the drive.
If the coupling manufacturer specifies closer toler- 1.10 Electrical connections

ances, always comply with them or obtain even
lower values if possible. The machine must be connected up according to
the accompanying circuit diagram. The marked
During alignment, remember that the length may earthing (grounding) screw must be connected to
increase as a result of thermal expansion in the the earth conductor. Installation is permitted by a
machine. This change in length is approximately qualified electrician only. Comply with the follow-
0,1 ,, per meter of machine length and per 10 ing points:
degrees Centigrade of temperature rise.
• VDE safety regulations or those of the local
In all cases, try to approach the ideal clear- safety authorities
ance values as closely as possible.
• Local electricity supplier’s guidelines regard-
Important points to be checked before starting ing protective measures
up:
• Phase sequence or direction of rotation of
a) Have pressboard transit keeper inserts machine field as stated on rating plate
been removed from the air gap?
b) Have the aligning screws been removed • Correct direction of rotation as stated on the
from the centering bell? machine’s data plate
When connecting the cables, make sure that no

mechanical forces can act on the machine’s con-
1.9 Changing direction of rotation
necting terminals. This also applies during as-
Before reversing the machine’s direction of rota- sembly work.
tion, it is important that the manufacturer be con-
sulted. Unused cable glands in the terminal box and ma-
chine must be protected against dust and mois-
In most cases the fan is of a directional pattern ture, and closed so that they cannot turn. Take up
and will have to be renewed. slack at all screw contacts and nuts.
Note that the rotary field also changes with a re- If current surges or vibration are to be expected,
versal in the direction of rotation. secure the cables with cable clips or racks. If the
plant is set up on flexible mountings, ensure ade-
If the machine is to be used in parallel operation, quate clack in the cables.
the sensing lead plug connections on the regula-
tor (U and W) must be changed over so that con-
nections U V W on the regulator again receive a
right-handed field. The rotary field will change at
the main terminals.

1.11 Starting up Where UN is the nominal voltage of the machine
expressed in kV.
1.11.1 Insulation resistance When testing insulation and measuring the wind-
After a long period out of use or in storage, the ings, these must be connected to the posts or
machine’s insulation resistance must be meas- bars as the case may be, so that these parts are
ured. tested as well.
Before starting up any machine, measure the Secondary connections such as measuring con-
insulation resistance of the winding between nections to transformers and all connections to
phases (if the star point is separate) and between regulating, protection or interference suppression
phase and earth. All parts not subjected to the circuits, must be tested separately. Each of these
measuring voltage must be earthed. connections must be checked individually at the
terminal strip. This also register the insulation
When measuring the insulation resistance, all resistance of the terminal strip.
connections (main connection, measuring connec-
tion, connection to regulator and protection or Use a maximum test voltage of 500 V DC for all
suppression circuit) must be disconnected from secondary and measuring connections. Insulation
the winding. resistance should not fall below 5 MΩ.
The suppression elements and measuring leads

must be disconnected during high-voltage insula- 1.11.2 Operating speed
tion tests and tests with insulation measuring ap- The machine’s speed must correspond to the
pliances. value stated on its rating plate. The machine must
run smoothly, both at no-load and when under
Measure at 500 V DC on low-voltage machines load.
(< 1 kV) or at above 2 kV on high-voltage ma-
chines (≥ 1 kV). If the drive machine runs at reduced speed, the
voltage regulator’s under speed protection cuts in
Due to the capacitive charge in the winding, the and de-excites the machine. Irregular running will
measuring unit indicates the correct insulation lead to deviations from the nominal ratings.
resistance value only after several seconds have
elapsed. Earth the winding immediately after the The machine is voltage-regulated and maintains a
measuring voltage has been switched off. voltage accurate to ± 1% in any condition between
no load and full load, even if its speed fluctuates
If the insulation values are too low, first check the by ± 5%.
terminal insulation for dirt and moisture. Clean or
dry them as the case may be, and repeat the In the case of special versions, the order values
measurement. confirmed by the manufacturer should be
adopted.
Damp windings can lead to current leakage, flash-
over or breakdown.
1.11.3 No-load operation
If insulation resistance on new, cleaned or
repaired windings is less than that stated be- The no-load voltage can be adjusted within a
low, drying out is needed (see Item 1.18, Dry- range of UN ± 8% by connecting the voltage set-
ing out the machine). ting rheostat to terminals s and t.
On low-voltage machines with a nominal voltage The voltage regulator ensures that the voltage
below 1 kV, and in the rotor winding, insulation remains constant as the machine warms up to its
resistance should not be less than 5 MΩ at a normal operating temperature.
winding temperature of 25°C.
In the case of medium- and high-voltage ma- 1.11.4 Parallel operation

chines with a nominal voltage equal to or greater Machines operated in parallel are equipped with a
than 1 kV, the insulation resistance in MΩ must be damper cage. They can be operated with identical
calculated using the following formula: or dissimilar machines or if necessary in parallel
with the mains.
R ≥ 3 + 2 x UN

The three familiar preconditions for parallel opera- 1.14 Operation
tion must be complied with:
• Identical voltages During operation, current-conducting and rotating
parts must be sealed with the covers provided for
• Identical frequencies
this purpose.
• Identical phase angles
Increased vibration may result from insufficiently
Matching can be carried out manually or by an
assert alignment, poorly fitted foundations or
automatic synchronizing device. For further de-
frame, or weak mountings. In addition, vibration
tails, see the supplier’s technical description.
can be introduced from the drive and non-drive
sides.
In parallel operation, a distinction must be made
between active and reactive load distribution.
1.15 Maintenance
Active load distribution depends only on the Before starting work on the machine make sure
speed characteristic of the drive and cannot be that it is switched off and take action to prevent it
influenced by the electrical machine itself. from being switched on again.
Reactive load distribution is determined by the Ensure that machine components which are
electrical machine’s voltage characteristic, accord- live during operation are at zero voltage (by
ing to load. earthing or disconnecting the wiring).
All work must be performed by qualified staff pos-

1.11.5 Loss of remanence sessing the necessary knowledge and experi-
ence.
If the auxiliary exciter machine (G3) has lost its
remanence, that is to say there is no voltage at
If there is moisture or dust in the terminal box, it
terminals UH1-UH2 and WH1-WH2, terminal I2
must be removed from the surface of the insulat-
(+) and K2 (-) must be excited briefly with a DC
ing parts. The reason for the accumulation of
voltage (1,5 – 12 Volt) while the machine is run-
moisture or dust must then be established and
ning.
rectified.
If severe dust occurs, the electrical machine

1.12 Power factor regulation should be blown through at regular intervals with
For operation in parallel with the mains the ma- dry compressed air, as it is running down to a
chine can be equipped with an additional auto- standstill.
matic power-factor regulator (for pre-set co phi
range, see test report). For further details, refer to Clean the machine’s surface regularly as well, to
the description and adjustment instructions for the prevent dust and dirt from building up and ad-
additional "Cos" power-factor regulating module versely affecting the dissipation of heat.
in conjunction with the "COSIMAT N" voltage
regulator. Make sure that the air inlets and outlets are not
obstructed during operation.
1.13 Interference suppression Apart from the bearings the dust filters (if in-
stalled) and the attached cooler, the machine
The machine comply with radio inteference re- requires no routine maintenance.
quirement "N" as stated in German VDE 0875.
Note that the standard of interference suppression If carbon brushes are installed on the machine in
is related to the quality of earthing. equipment designed to perform various monitoring
functions, they must be checked for wear at regu-
Disconnect suppressor capacitors, measuring lar intervals.
transformers and regulators during high-voltage
insulation tests or if insulation measuring equip- If the machine has add-on equipment, for example
ment is in use (if the test voltage reaches 80% of a cooler, the additional maintenance instructions
the factory’s test voltage). issued by the manufacturers of this equipment
must be complied with.
Like any other machine, the electrical machine

requires to be treated with care.

1.16 Bearings Machines which have not been run for very many
hours must be re-lubricated at least once a year. If
1.16.1 Ball and roller bearings the stated re-lubricating interval is below 1,200
The machine is fitted with anti-friction bearings. hours, re-lubricate twice a year.
The DS has a floating bearing, the NDS a fixed
bearing. Under adverse operating conditions, e.g. a humid
atmosphere, relatively high dirt accumulations,
If the bearings on either side are of the deep severe vibration loading etc., the re-lubricating
groove ball bearing type, they are pre-loaded in interval must be reduced accordingly. If the per-
relation to each other by spring elements, this mitted coolant temperature is exceeded by app.
ensures smoother running and reduces the nega- 15°C, the re-lubricating interval must be halved.
tive effects of external sources of vibration on the
bearings. Deep-groove ball bearings are installed • Re-lubricating quantity
at both bearing points only to special order.
The machine’s bearings must each be re-
The standard bearing specification is as follows: lubricated with the amount of grease stated. Re-
on the drive side, a roller bearing, on the non- move expelled grease from the bearing points.
drive side, a ball bearing or a duplex bearing con- When re-lubricating the bearings, run the machine
sisting of one roller bearing an one ball bearing. if possible at half speed for one hour to distribute
the grease effectively. During this period, check
Each of the machine’s bearings is normally pro- the temperatures of the bearings and compare
vided with a relubricating device. If a duplex NDS them with the temperatures recorded before re-
bearing is installed, note that there are two grease lubricating.
nipples for relubricating. Refer to the appropriate
column in the lubrication chart for the correct vol-
ume of grease per nipple. Lubrication chart
Re-greasing should be carried out with a grease Type Lubrication Re-lubrication intervals in
gun at the nipples provided on the machine. points* hours for machine running
Quantity in speed of:
A regulator is installed to control grease volume, g
bear-
Double bear-
so that old grease is expelled from the bearing.

500-600 min-1
750-900 min-1
1000-1200
1500-1800
Before re-greasing, clean the nipple so that
Single
dirt cannot enter the bearings.
-1
min-1
DIG
min
ing
ing
Where possible, apply grease when the machine

is running at reduced speed, unless this repre- 120/
sents a hazard for the operating personnel. … 60 40 2500 2000 1500 1000
121
• Re-lubricating the bearings 130/
… 80 60 2500 1500 1200 800
Ball and roller bearings are supplied ex- factory 131
packed with high-quality anti-friction bearing 140/
grease and are therefore ready for immediate … 100 60 2000 1500 800 600
operation. Machines with re-lubricating devices 141
bear a plate on which the following information is 150/
stated: … 100 60 2000 1000 800 600
151
Re-lubricating interval in hours of operation
Quantity of grease 156 100 60 1800 900 700 500
* In the case of double bearing, the amount of grease stated in
Type of anti-friction bearing grease the "double bearing" column is to be injected into each of the
grease nipples.
• Re-greasing interval
Bearing must be re-lubricated regularly in accor-

dance with the specified re-lubricating intervals
(see chart).

• Ball and roller bearing greases disk should be rigidly attached to the shaft. Do not
remove new bearings from their packs until just
On delivery, the bearings are lubricated with high- before they are installed. Do not wash the bear-
grade, lithium-saponified grease of Grade 3 con- ings out, as the anticorrosion agent applied to
sistency )NLGI classification). The factory uses them is compatible with most customary anti-
Shell Alvania R3 for this purpose. friction bearing greases.
Clean the parts of the bearing that are to be re-
The grease channels and the channel between installed. Before fitting the bearing, check for di-
the nipple and bearings are filled with anti-friction mensional accuracy and lack of distortion at the
bearing grease before leaving the factory. The bearing seats on the shaft and in the housing.
following alternative types of lithium-saponified
anti-friction bearing grease may be used: When single-piece bearings (e.g. deep-groove
ball bearings) are installed, the force exerted to fit
Shell Alvania R3 them must always be applied to the firmly located
Arcanol L71 race, which has to be mounted first. Forces ap-
plied to the free-moving race have to be transmit-
Or a lithium-saponified brand-name grease of ted through the balls or rollers, which can damage
equivalent specification, heat-resistant up to at them and their tracks.
least 130°C and complying with German Industrial
Standard DIN 51825. Installation of separable bearings (e.g. roller bear-
ings) is more straightforward. The two races can
Recommendation: be installed separately. A screwing movement
when assembling them helps to avoid rub marks.
Always re-lubricate the bearings with the same
selected brand of grease. When fitting the bearing on the shaft, heat it to
about 80°C in an oil bath, oven or by a suitable
inductive heating method. Make absolutely sure
• Dismantling the bearings that it is located centrally and in positive contact
with the shaft shoulder.
During shaft production, the bearing seat and the
bearing stop shoulder on the shaft are subject to Once they have cooled down, pack the bearings
particularly stringent quality control. This is essen- fully with grease. The inner and outer bearing
tial to maintain the accuracy of shape needed to covers must each be filled with grease to approx.
keep the bearings fully operational. When disman- 50% of their full capacity.
tling the bearings, it is therefore important to han-
dle the bearings and bearing rings with particular • Monitoring the bearings
care, otherwise the bearing seats on the shaft and
bearing plate could become damaged. The first indication of damaged bearings is usually
a noticeable change in temperature or running
To simplify dismantling, the parts can be heated behaviour, or noise and vibration if bearing dam-
uniformly all round to a temperature of app. 80°C. age has reached and advanced stage.
Do not install bearings previously removed, but
renew them. Recommendation:
• Assembling the bearings Monitor the bearings by measuring transmitted

noise and vibration at regular intervals, and com-
Bearings must only be renewed by a qualified pare the readings with those taken on previous
person possessing the necessary knowledge and occasions.
experience, working in a dust-free environment,
on a clean surface and using suitable tools includ-
ing metric wrenches.
The grease and bearings must be kept free of
impurities, otherwise they will wear out faster and
possibly even fail. The correct arrangement of the
bearing components must be retained, this ap-
plies particularly in the event of repair work.
When renewing bearings, install original type-

approved bearings only, and maintain the correct
amount of bearing play. The grease regulating
1.17 Drying out the machine If no improvement in the insulation resistance is
registered after a running period of approx. 2
To protect the machine against moisture, the built- hours, the machine must be dried out additionally
in heating should always be switched on when the with dried air supplied from the outside.
machine does not emit any heat of its own. Even If this in turn does not increase the insulation re-
a slight increase in the temperature of the air in- sistance after approx. 4 hours, the machine must
side the machine will prevent moisture condensa- be dried out by passing an electric current through
tion on the insulating components. the stator and rotor windings.
If the machine’s insulation value drops below that
stated in the chapter "Insulation resistance", the However, this task requires special knowledge
machine must be dried out. and must therefore only be performed by person-
nel that has received specific training. Please
In many cases it can be dried suitably using its contact our service organisation in this case.
own ventilation system, but it should not be elec-
trically live while this is being carried out. De-
For additional information on bearing renewal
excite the machine as indicated in its circuit dia-
or special operating conditions such as run-up
gram. Operate the built-in heating when drying out
synchronisation, rapid excitation or de-
with the machine’s own ventilation system.
excitation, please do not hesitate to contact
our engineers.

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

Dreieich Office
Benzstraße 47-49
Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40

Enclosure to Operating Instructions
Advise for Commissioning

POD-geno-AvK-eng-DSG29144(ohne Cosimat).doc
Generator with vibration absorbers on in order to avoid relative movements
foundation between the cable fixing and the terminal
box.
By connection of the cables it must be

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

Generator with vibration absorbers on
frame base
By connection of the cables it must be In order to ensure that the movements do

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

Connections
Stützer für Innenanlagen

Insulating supports for indoor use
Anzugsdrehmoment / tightening torque M12, 50-70 Nm
Anzugsdrehmoment / tightening torque M16, 90-110 Nm
6 Kt. Schraube: Stahl 8.8
hexagon bolts: steel 8.8
Durchführungsklemme DIN 46265

Duct terminals
Anzugsdrehmoment / tightening torque M12, 20 Nm

Anzugsdrehmoment / tightening torque M16, 40 Nm
Anschlussbolzen: Ms / connection bolts: brass
Anschlussmutter: Ms / connection hex. Nut: brass
Cable connection acc. to DIN 46200 Using the Protection switches Q1, F1, F2
Elastic parts, such as spring washers, can The purpose of these switches is to protect
be used in the electrical connection, the voltage transformers T24 (Q1) and the
however, only on one side of the clamped auxiliary exciter winding (F1, F2). In case of
conductor. If necessary, additional failure, these switches will lead to a quick
washers are to be used. The other side is de-excitation of the machine.
for current conduction, why only washers
or security locking plates of copper-zinc- These switches are not to be used for de-
alloys must be used. exciting the machine during operation or
maintenance!
By electrical connection with eyelet rings,
the eyelets have to be protected by
washers on both sides against bending. Open star point
The voltage transformer T24 has to be

De-excitation disconnected and the cables sufficiently
insulated! De-excite the machine as
described above.
Open the bridges UH1-24 and WH1-14 on
the terminal strip X2. De-excitation with
No tests are to be performed with open
extern switch takes place on these
star point! The correct connection of the
terminals, too.
power cables can be checked with
appropriate equipment.

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

Maintenance of Earthing Fault only possible after agreement with the
Monitoring supplier.
Optimum maintenance and care of the

brushes and slip rings is the base for
smallest wear. The maintenance must take
place in certain time intervals. The
frequency of the maintenances depends
on alternator size as well as on load and
ambient conditions.
Note:
Brushes are subject to wear and tear and
The Earthing Fault Monitoring is mounted
must be cleaned by air (pressure or
on the NDE of the machine.
suction) from time to time. Routine checks
every 3 months is recommended by AvK in
Attention:
order to estimate the necessary time
intervals during the actual operation
Maintenance works must be performed
conditions.
only during standstill of the machine.
All brushes and holders must be checked
for free movement. Blocked brushes may
lead to damage.
Worned out brushes must be replaced in

time in order to avoid damages on the slip
rings and to ensure the perfect function of
the Earthing Fault Monitoring. New brushes
need grind-in with the slip rings. The use of
larger brushes than originally mounted is

Electrical Machines with two shaft ends Anti - condensation heater:
Bearing currents by electrical machines The anti condensation heater is to be

with two shaft ends must be avoided. connected according to correct rating
and supply voltage.
AvK recommends an insulated coupling Please refer to rating plate of the
mounted on the NDE. machine.
Another possibility is that all bearings of the Control of the anti – condensation heater
NDE aggregate are insulated. should be done that the heater
- is switched on after the machine has

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

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

long assembled into two brackets made of
stainless steel as per our drawing no 31522,
heaters wired in parallel by brass brackets,
silicon insulated connection cable
3000mm long.
Number of heater elements is according
to required heating power.
Technical data of the heaters
Heater sheath: Chrome-Nickel-Steel

AISI 321
Heater wire: NiCr 8020, Mat. no.: 2.48869
Insulation material:
pure magnesium oxide, highly compacted
Connection:
threaded bolt M4 with silicon insulated
cable
Tolerances
Diameter of heaters: 8,5mm ± 0,15mm

Straight length of
heaters: 500 ± 2 %
Wattage per heater: 500 Watt ± 10 %
Total wattage (4 heaters):1000 Watt ± 10 %
Voltage: 230 Volt
Dielectric strength: 1250 V
Final test: per standard
DIN EN 60 335
Bolting torque for fixing screws Dust filter made of metal fabric
If no further indications are made , use the Description

following bolting torque for connections of
fixing screws and fixing nuts: Design of the filter
The frames and the plates of the filter are

fabricated of:
screws screws • Constructional steel with zinc coated
property class property mesh wire
8.8 class • Stainless steel with stainless steel mesh
4.6 wire alternatively depending on
M4 3,0 1,1 application conditions
M5 3,5 2,2
M6 9,0 3,7 Type of filter
M8 18 9,0
M10 45 18 B1 according to DIN 24185 / part 100
M12 50 31 EU2 according to DIN 24185 / part 2
M16 110 75
M20 250 150 Medium degree of deposition 65 ≤ 80 %
M24 440 255
Maintenance
M30 980 510
M36 1730 890
The maintenance intervals depend on the
M42 2700 1450
local dust accumulation. The dust
protective filter plates have to be cleaned
starting torque in Nm
with the usual commercial detergents.
Cleaning with high-pressure cleaning
Values according to VDI 2230 calculated
devices is also possible.
considering the maximal admissible
surface pressure under the screw head
Caution:
and a frictional co – efficient µ ges = 0,125
Do not wet the filter plates with oil!
Observe the instructions for pollution
control.
The following detergents can be used

when cleaning mechanically:
Calgonit / Somat / Topmat 760 (or

equivalent)
If only a manual cleaning is possible, use

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

protective filter system is indispensable
for the safety in operation of the electrical
machines

All wedges welded
Fixing pins Ø2
Enforcement over L500 2 pieces
P5 2/1 angle bracket Screen 20*20*2
B 25-1
1
10
a
20
2*Ø7-200
20
3*Ø7-400
=
4*Ø7-600
20*3
5*Ø7-800
L
a
6*Ø7-1000
7*Ø7-1200
=
20
7
10
20 20
Microcellular rubber 10*3
28
glued at installation
1.5
1* Ø10 borehole (outlet)
20
R1
ax
10 = = 10
m
38
Medium of the filter

P1 Material: St. 37 / round wire Ø 0.28 galvanized / mesh width 6-8 mm Frame and
screen St. 37 not galvanized
P2 Material: V4A 1.4571 / round wire Ø 0.28 / mesh width 6-8 mm Frame and screen like
above (marine)
P3 Material: Monell CuNi 2.4360 / round wire Ø 0.28 / mesh width 6-8 mm Frame and
screen V4A 1.4571
P4 Plastic PP / mesh width 6-8 mm Frame V4A 1.4571

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

Dreieich Office
Benzstraße 47-49
Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40

Regulator Description
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
 Copyright 2002 ABB. All rights reserved.
UNITROL 1000-15
User’s Manual
Automatic Voltage Regulator

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

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

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

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

This page is intentionally blank.

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

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

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

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

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

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

dangerous situations.

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

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

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

R
Generator or motor excitation with

PMG or external supply.
PMG
SM E
UNITROL 1000

R
Replacement of voltage regulators for

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

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

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

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

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

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

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

2.3.3 Device connections
Terminal designation Signal Circuit

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

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

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

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

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

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

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

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

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

2.3.4 Digital inputs
Input function Description

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

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

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

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

2.3.5 Digital outputs
Output function Description

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

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

2.3.6 Analog inputs

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

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

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

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

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

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

2.3.7 Analog outputs

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

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

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

2.4 Software
2.4.1 Operating modes

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

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

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

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

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

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

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

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

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

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

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

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

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

1s 1s
Alarm (MODBUS) Output

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

Signal field flashing
Field flashing off level

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

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

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

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

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

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

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

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

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

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

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

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

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

- Minimum
- Maximum
- Ramp Rate
Mode Preset value

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

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

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

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

Var SPmin

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

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

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

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

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

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

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

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

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

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

Frequency
UM Calc
f

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

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

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

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

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

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

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

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

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

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

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


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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

I/Os
Din from Ain

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

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

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

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

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

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

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

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

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

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

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

MAIN, TUNE ➠ PF/Var/PQ LIMITER

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Software Revisions
Control:
Panel: Click window to continue

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Setup \ Field Flashing
Close
Field Flashing Off Level 0.0 %

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

k
ic
None
cl
Excitation Current
PWM
Fbias

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

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

• Adjust PSS
Setup \ PSS
Close
PSS_Select Activation Level

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

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

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

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

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

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

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

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

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

0 0 0 0 Bit
Hex

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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


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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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


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

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

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

List of possible faults
Possible causes Checks, action

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

• Regulator fault − Check operating mode. For field flashing

− Check setpoint
− Check parameters of Auto regulator

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

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

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


7 APPENDIX
7.1 General Data

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Rotor mounting/dismounting
Rotor Dismounting and Mounting REV.: B
CONTENTS:
• INSTRUCTION FOR ROTOR DISMOUNTING AND MOUNTING,
MOUNTING, SIDES 1-
1-2
• ASSEMBLY DRAWINGS:
DRAWINGS: T67M00600XY,
T67M00600XY, T67M00100XY SIDES 1-
1-3
• ASSEMBLY DEVICE DRAWINGS: T67M00101XY, T67M00102XY, T67M00103XY,
T67M00104CY,
T67M00104CY, T67M00104FY, T67M00110XY,
T67M00120XY,
Instruction for Rotor Dismounting
and Mounting Before dismounting the
bearings, disconnect PT100
The following instruction refers to the attached on bearing housing (16)(20).
drawing T67M00100XY sheet 1-3 respectively
as well as table of torques. (i) Lift upper part of bearing housing (9) on
DE after loosening the screws (10).
The assembly works must be
carried out carefully by trained (j) Lift upper part of bearing housing (11) on
staff only. Before starting the NDE after loosening the screws (12).
works, read the complete
instruction. (k) Dismount upper part of bearing shell (13)
on DE.
Please observe the following
recommendations: (l) Dismount upper part of bearing shell (14)
- Use only suitable tools on NDE.
- Windings and bearing surfaces must
be protected against damages (m) Slightly lift rotor on DE (for discharging).
- Apply generator stable on stator core Dismount from lower bearing shell (15) as
as shown in T67M00100XY sheet 1. well as bearing housing (16) by loosening
Support only on longitudinal rips, of the fixing bolts (17).
where screws are mounted.
(n) Lower rotor and support it on sleeve
Please pay attention to the additionally bearing cover (18).
enclosed installation manuals.
(o) Unscrew the lower part of the bearing shell
Further, please observe additional mounting (19) on NDE by slight lifting (discharging).
and dismounting instructions of our sleeve
bearing manufacturer. (p) Remove the lower part of the bearing
housing (20) after loosening the fixing
bolts (21).
1. Rotor Dismounting
(q) Lower rotor on sleeve bearing cover (22).
(a) Dismount assembly cover (1) on NDE by
loosen screws (2). (r) Dismount air outlet box (23) by loosening
the screws (24).
(b) Drain the oil of the bearings on DE and
NDE. (s) Lift the rotor on DE for discharging.
After loosening the fixing bolts (25) the
(c) Dismount axial air filters (30) on NDE. bearing shield (26) has to be removed
towards DE together with the sleeve
(d) Insert Pertinax and respectively HGW- bearing cover (18) and with the help of the
sheets (at two positions at lower range existing jack bolts and the pipe (27) on the
through the whole core length) into air gap DE bearing shield. Change the support
and fix it (air gap is about 10 mm on 8-pole any time if necessary. Dispose rotor
rotors and 9 mm on 10-pole rotors). carefully on protection sheets mounted on
item (d). Then take of the bearing shield
(e) Mark the cables on the rotating rectifiers (26).
(3) and disconnect them.
(t) After loosening the fixing bolts (28), also
(f) Dismount the rectifier carrier incl. rotating dismount and deposit the fan (29) towards
rectifier (4). DE.
(g) Dismount seal carrier (5) after loosening (u) Dismount the cover of terminal box (31).
the screws (6). Mark the cables, wired between NDE-
shield and terminal box, and disconnect
(h) Remove seal carrier (7) after loosening the them.
screws (8).
Rotor Dismounting and DIG 167 acc. to drawing Seite / Page 1

Mounting T67M00100XY sheets 1-3 03.2007
(v) Unscrew the bolts (32) on terminal box
and lift the housing (33). Then unscrew Do not support on rotor
the bolts of terminal box supports (34)(35) bearing surface!
and lift the base plate (36). Take care of the stator coils,
even slight collisions may
(w) Lift the rotor on NDE for discharging. cause damage!
After loosening the fixing bolts (37) the
bearing shield (38) has to be removed Step 3:
towards DE together with the sleeve Mount a further extension pipe on the
bearing cover (22) and with the help of the generator shaft, lift the rotor again, move it
existing jack bolts on the DE bearing forward to NDE till the rotor core is completely
shield. Change the support any time if outside the stator.
necessary. Dispose rotor carefully on
protection sheets mounted on item (d). Step 4:
Then take of the bearing shield (38). When the rotor is supported like prescribed,
change position of crane from DE to NDE.
(x) Dismount air guiding element (39). Now the rotor can be removed and deposited.
2. Rotor – Removal
When depositing the rotor,
With the help of the removing devices support on the shaft. Never lay
- alignment part DE (50) down the rotor on core!
- alignment part NDE (51)
- two half shells DE c/d/e-size (52)
- two half shells DE f/g/h-size (53) 2.2 Dismounting from NDE to DE
- one bushing NDE (54)
- two adapter pipes (55) As per description from DE to NDE, only the
- one connection pipe (56) reverse direction.
- Bolt EN 24017 M16x60 (57)
- Bolt EN 24017 M8x25 (58) 3. Rotor Mounting Respectively
- Bolt EN 24017 M16x40 (59) Bearing Shield: In Reverse Order
- Bolt EN 24017 M8x40 (60)
Table of torques
which are part of generator manufacturer
supply. (optional equipment) Torques for bolts used for rotor dismounting
and mounting:
Pay attention to the drawings of
T67M00100XY sheet 2! A secure
handling of the rotor with help 1. Bearing bolts: s. table respectively
of the extension pipes is only description in the documents of Firm Renk
warranted if mounted as shown. 2. Fixing bolts bearing shield of generator
Differences could cause damages on the Housing, support of the exciter.
rotor or lead to severe injuries caused by Fastening housing of exciter on support
accident.
2.1 Dismounting from DE to NDE

Bolt size Torque [Nm]
Step 1: M16 175
By crane, remove the rotor towards NDE (see M20 330
drawing no. T67M00100XY sheet 3). Lower M24 570
rotor in the air gap on HGW or similar. For M30 1150
support mount alignment part NDE (51).
M36 1700
Step 2:
Mount the first adapter pipe (55) on the
generator shaft, lift the rotor again, move it
forward to NDE and lower it on supports on
prescribed positions.
Rotor Dismounting and DIG 167 acc. to drawing Seite / Page 2

Mounting T67M00100XY sheets 1-3 03.2007
Bearings
Power transmission
Plain bearings
Installation and Operating Instructions ZF
Parts List for Flange Mounted Bearing ZF
1.1 Upper bearing housing* 15.1 Seal carrier

1.2 Lower bearing housing* 15.2 Seal carrier retaining screws*
1.3 Bearing housing retaining screws* 20.1 Floating labyrinth seal*
1.5 Sealing plug with seal* (Oil inlet for circulated oil) 20.2 Spring key for floating labyrinth seal*
1.6 Sealing plug with seal*(Temperature sensor port) 21.1 Floating labyrinth seal (machine side)*
1.7 Sealing plug with seal* 21.2 Spring key for floating labyrinth seal (machine
(Connection for heater, sump thermometer or cooler) side)*
1.8 Sealing plug with seal* (drain) 25.1 Bolt on baffle
1.9 Sealing plug with seal* (oil fill) 25.2 Bolt on baffle retaining screws*
1.10 Oil level sight gauge (or oil outlet for circulated oil) 30.1 Machine seal
1.11 Oil sight window* 30.2 Machine seal strip
1.12 Eye Bolt* 30.3 Machine seal retaining screws*
5.1 Bearing shell upper half* 40.1 Upper bearing housing retaining screws
5.2 Bearing shell lower half* 40.2 Lower bearing housing retaining screws
5.3 Anti-rotation pin* 45 Machine shield
10 Loose oil ring
*These parts can only be supplied as sub-assemblies. Spares parts are listed in section 11
990225/h520
2
1 Safety Recommendations
Zollern flange bearings (type ZF) are incorporated into various types of machinery, any safety regulations specific to the
machinery must be observed.
During bearing operation, assembly, maintenance and repair, accidents and injuries must be avoided at all costs. The following
points require special attention:
During maintenance and repair ensure that rotating machinery is at a standstill, isolated from electrical supply with
interlocks such the supply cannot be resumed unintentionally.
Loads and speeds must not exceed those specified in Zollern’s data sheets, drawings or calculation sheets.
Rotating parts must be fixed so that accidental movement is not possible.
BEWARE: after use bearings will be hot, there is a danger from burning during repairs and maintenance if the bearing is
not allowed to cool.
The shaft tolerances set out in our specifications and drawings may not be exceeded.
The bearing may become detached if screws are allowed to loosen. Tighten the screws to the specified torque.
Alterations to the ZF bearing may only be carried out with the express permission of Zollern, who must also be consulted in the
event of load specifications being exceeded. Our qualified team of fitters can carry out repairs and service if required avoiding
errors caused by untrained personnel.
2 Bearing Types and Designations

Type Z Bearing for horizontal mounted shaft
Housing F Finned end flange bearing
Cooling N Natural convection
Z Forced oil with external cooling
W Water cooler in oil sump
Lubrication L Cylindrical bore with loose oil ring
Thrust bearing B Plain white metal with oil grooves
K Tapered pad for bi-directional rotation
D Tapered pad for uni-directional rotation
A Round tilted pads, spring supported
Q Without thrust bearing
Note Insulated bearing shells are designated ‘insulated’
Example : Finned end flange bearing with forced oil lubrication externally cooled having plain
cylindrical bore with loose oil ring. Tapered thrust pad for bi-directional rotation size 9,
ZFZLK 9-90 shaft diameter 90mm
3 Introduction
Please pay careful attention to all points covered by this manual to ensure the safe and efficient operation of the bearing. Care
needs to be taken to keep all bearing parts and the workplace clean. Provision is made for thermometers (1.6, 1.7), oil level
gauges (1.10), oil inlet (1.5) and outlets to be fitted to either side of the bearing. These devices can be fitted to either left or the
right as required. Where a bearing is force oil lubricated, the oil outlet pipe is fitted into the tapping for the oil level gauge (1.10).
The oil drain plug (1.8), which can also act as an oil flow connection, is positioned at the centre underneath the bearing.
With electrically insulated bearings, there is a non-conductive layer on the spherical seat of the bearing housing. This layer is
both wear-resistant and temperature-resistant. The shaft seals (see chapter 6 - “shaft seals”) and the anti-rotating pins (5.3) are
manufactured from non-conductive material and prevent any spark erosion of either bearing shell or. Any temperature control
instrumentation installed by the user should be insulated using appropriate measures, such as isolated protective piping and
plastic screws. Zollern can, of course, provide help as and when required.
Eyebolts are fastened to the upper part of the bearing to assist handling of the complete and assembled bearing. It is important
to remember that they are not suitable for the handling of the assembled machine and that the eyebolts are only to be used as
tension elements.
4 Packing
All bearings are delivered fully assembled without oil. The oil ring (10) and other accessories are packed as separate items. The
bearings are protected against corrosion and other influences by a preserving film, according to individual application.
3
5 Installation
Once the upper housing (1.1), the seal carrier (15.1), the shaft seals (20.1) and the bearing seal (5.1 and 5.2) have been
dismantled, carefully clean the interior of the bearing and the bearing shell and check for any damage caused during transport.
Ensure that the shaft is clean and that dimensions and tolerances correspond to our recommendations. We recommend that the
appearance of the bearing surface on the shaft is checked and that it is checked that non-moving seals have not become
jammed in the shaft (see chapter 6 “shaft seals”).
Proceed with installation as follows:
Align the cleaned lower part of the housing (1.2) with the machine frame and fasten.
Secure the machine seal (30.1) inside the machine housing (the machine seal is not supplied as standard and must
therefore be ordered separately).
Apply a film of oil to both the spherical seats in the lower part of the bearing housing and to the lower part of the bearing
shell (5.2) (use the same oil as is to be used during operation of the bearing).
Place the lower part of the bearing shell onto the shaft seat and turn it to the correct position in the lower part of the
housing. Take care that thrust bearing surfaces are not damaged whilst the shell is turned.
Align the surface of the shell with that of the housing.
Now follows assembly of the loose oil ring (10), which must first be disassembled.
Position both halves of the oil ring on the shaft and around the lower half of the shell using the notch provided, then press
both halves together on the dowel pins. Following this, tighten the fixing screws to the following torque values:
Bearing Size 09 - 14 18 - 28
Torque (Nm) 1.4 2.7
Apply a film of oil to both the shaft seat and the upper part of the bearing shell (5.1). Lower the shaft into the lower part of
the shell (5.2) and place the upper part of the shell onto the lower part (it is impossible to turn both halves of the shell
together as they would become misaligned).
Insert the flange-side seal (21.1), this is usually a floating labyrinth seal (see chapter 6: “shaft seals”).
Coat the surface of the split line in the lower part of the bearing housing with a thin film of non-hardening sealing
compound.
Very slowly lower the upper part of the housing (1.1), rotate it in the machine frame and position it on the flange. Ensure
that during lowering the already assembled flange-side seal slides locate into the groove provided. Avoid jamming at all
costs. The upper part must be correctly aligned (to ensure this one possibility is to pass a rod through the upper through
hole and align accordingly). Tighten the cover screws (1.3) crossways and then tighten the flange screws (40.1) to the
following torque values :
Bearing size 9 11 14 18 22 28
Torque (Nm) 89 89 215 420 725 1450
The cover screws (1.3) are to be tightened crossways as follows:
Bearing size 9 11 14 18 22 28
Torque (Nm) 71 71 172 336 580 1160
With machines that are prone to vibration, it is essential that measures be taken to prevent screws from loosening. To this end
secure with Loctite or similar thread locking compound.
Prepare the exterior floating labyrinth seal (20.1) for assembly in the same way as the flange-side seal and attach to the
shaft before fastening the seal carrier (15.1) to the housing as follows.
Coat the split lines and flange surfaces of the seal carrier with non-hardening sealing compound.
Place the seal carrier around the floating labyrinth seal, push both into the bearing housing and tighten the seal carrier
screws (15.2) to the following torque values :
Bearing Size 09 - 14 18 - 28
Torque (Nm) 10.5 26
4
5.1 Additional Information for Bearings with External Oil Supply
When using an external oil supply the pipe diameters should be chosen such that the inlet flow does not exceed 1.5 m/s and the
outlet flow 0.15m/s.
If the inclination of the oil outlet pipes for structural or design reasons cannot be set to 15° , pipes with correspondingly larger
diameters need to be used. Pipes with inclinations or diameters which are too small may create back-flow, which could in turn
lead to overflowing or leakage.
Heat-treated (welded or hot-worked) pipes and/or those showing any signs of rust or dirt must be scoured and cleaned prior to
assembly. Following assembly of the pipes the entire oil circulating system must be flushed to prevent dirt entering the bearing
or fittings.
Prior to cleaning all measuring and switch fittings (pressure control, flow gauge) and their connections must be removed. The
bearings must not be left intact during cleaning, and following cleaning all filters must be rinsed. All connections to the bearing
must be free of vibration and tension.
5.2 Additional Information for Bearings with Water Cooler in the Oil Sump
When attaching the water cooler care must be taken to ensure that there are no leaks from the cooler or its connecting pipes.
The joint seals must not be damaged. During fitting a stop tap or valve should be provided in the inlet. Any oil should be free to
drain from the housing (no pressure should be required). The cooling flow can be in either direction.
6 Shaft Seals
Zollern bearings can be supplied with various seal types or seal systems depending on the required application, with seals
conforming to DIN 40050 or IEC 529. Special seals can be supplied for particular applications on request.
6.1 Floating Labyrinth Seals

For standard applications ZF bearings are equipped with floating labyrinth seals (see fig. 2) which achieve IP44. The labyrinth
seals float on the shaft at circumferential speeds above 100 m/s. They are manufactured from a rigid, unbreakable and
temperature resistant polymer. The seals are seated within a seal carrier or directly seated in the housing such that they are not
subject to loadings due to radial shaft displacements.
Oil drain holes are provided in the lower part of the floating labyrinth seal. An anti rotation pin on the split line prevents the seal
from being assembled incorrectly and damaged.
Build the seals up prior to bearing assembly so that the hook and eye of the spring key (20.2 & 21.2) are separated.
Prepare the seal for installation and coat the surface of the split line and the exterior of the spring guide (see fig. 2) with a
thin layer of non-hardening sealing compound.
Place the lower part of the seal onto the shaft and turn it into the correct position (the oil drain holes in the seal must be
facing towards the bearing and the anti rotating pin must sit in the groove of the split line).
Place the upper part of seal onto the lower
Insert the spring key through the sealing groove and lock into place.
Check the alignment of the seal and housing split line
6.2 Floating Labyrinth Seal with Bolt on Baffle

The bolt on baffle can be combined with either a floating labyrinth seal (chapter 6.1) or a rigid seal (chapter 6.4) to achieve IP55.
The inserted seal strip is temperature resistant withstanding high circumferential speed. The coefficient of friction is minimal as
is the ‘stick/slip’ coefficient. The electrical insulation properties are very good and independent of temperature and
environmental influences.
5
Insertion to be done as follows:
Spread the sealing compound onto the surface of the split line and coat the movement surface with the seal carrier of the
floating labyrinth seal (fig. 3)
Next gently press the lower part (recognised by the drain hole) from underneath against the shaft and tighten the fixing
bolts equally.
Finally position the upper part, align on the split line and attach with the bolts.
6.3 Floating Labyrinth Seal with Labyrinth Ring

The labyrinth is clamped onto the shaft and inserted into a groove in the seal carrier of the floating labyrinth seal (fig. 4), thus
preventing dirt and water from entering the bearing. The groove can be filled with grease where necessary.
After placing onto the shaft the labyrinth ring must be so placed that it is not possible for it to run into the groove. The thrust
movement of the shaft is limited.
6.4 The Rigid Seal

Fig. 5 shows a rigid seal with two separate labyrinth systems. Where axial movement is minimal a shaft collar can be provided
between the labyrinths.
A thin layer of sealing compound initially retains the rigid seal. During assembly the lower half of the seal is lightly pressed
onto the shaft from below and the screws then tightened (during operation the shaft is raised).
ATTENTION The baffles must be removed during assembly and disassembly of the shaft or damage to the shaft may ensue.
6
7 Commissioning
Having removed the oil sight glass (1.11) or the plug (1.9) fill to level with the recommended oil grade. The oil is at the correct
level when it reaches the middle of the oil level glass (1.10). The minimum oil level is when the oil only reaches the lower part of
the sight level glass when the machine is stationary.
WARNING
Insufficient oil level will lead to ineffective lubrication, bearing overheating and subsequent damage leading to failure. Too high a
level of oil will not hinder the operation of the bearing, but could lead to leakage at the seals. Prior to commissioning of the
bearing it must be checked for leaks. All oil port plugs and securing screws are correctly fitted and tightened.
ATTENTION
Should, at any time during commissioning or operation, the bearing temperature exceed that specified by Zollern the machine
should be stopped and the causes investigated.
8 Maintenance
The oil level must be checked at regular intervals with the machine at standstill. The minimum oil level is when the oil only
reaches the lower part of the sight level glass.
The bearing housing must be kept clean as heat transfer can be hindered by dirt and dust leading to bearing overheating and
subsequent damage leading to failure.
Should, during operation, there be unusual variations in bearing temperature or oil level the causes must be investigated.
Our technicians are available should any assistance be required.
8.1 Oil change intervals

For self contained and bearings using mineral oils we recommend flushing and oil change after 8000 operating hours, for forced
oil lubricated bearings we recommend an interval of 20000 hours. Longer intervals may be possible subject to Zollern approval.
Shorter intervals are necessary where there is frequent starting or where oil temperatures are high or where there is an
excessively dirty environment. To change the oil, take out the oil drain port which is positioned at the centre beneath the bearing
(allow the oil to drain whilst hot). Should unusual oil discoloration or smell be apparent the causes must be investigated. Should
any chemical cleaning compounds be used these must be thoroughly flushed away prior to further operation.
The oil is refilled through the oil sight glass (1.11) or plug (1.9). Use only the recommended oil grade as shown by the
manufacturer’s plate. The oil is at the correct level when it reaches the middle of the oil level glass (1.10). There is always a
possibility of overfilling - too high a level of oil will hinder the operation of the bearing.
WARNING
If regular checks are not made there is a chance of insufficient oil leading to ineffective lubrication, bearing overheating and
subsequent damage leading to failure.
8.2 Inspection
Should unusual oil colour changes or increases in temperature be apparent an inspection must be made. Remove the upper
half of the bearing housing (1.1) leaving the lower half in place. Prior to disassembly thoroughly clean the bearing casing such
that no dirt can accidentally enter the bearing itself.
8.3 Disassembly
Loosen the fixing screws to the upper half of the bearing (40.1) and the split line screws (1.3) and the screws (15.2) on the
upper half of the seal carrier.
Raise the upper half of the housing such that the bearing is split then completely remove the upper bearing housing from
the frame.
Remove the upper part of the seal carrier (15.1).
Dismantle the floating labyrinth seals (20.1 & 21.1) by raising the upper half and tilting it then open the spring key and
dismantle together with the lower half.
Carefully raise the upper half of the bearing shell (5.1). Release the loose oil ring (10) screws, separate and remove both
parts.
Remove any probes or sensors if present.
Raise the shaft far enough to give sufficient clearance to turn the lower shell (5.2) half through 180° and lift it away.
8.4 Visual Check

During disassembly check that all bearing surfaces remain in good condition. Bearing in mind the length of bearing service the
shell should show consistent polishing of the surface. Any light score marks should be smoothed prior to rebuilding of the
bearing. The shaft seals should be changed should they show excessive wear or have broken edges.
7
9 Transport and Storage
During transportation of the machine the bearings should never be subject to shock loading, and must be protected from
environmental humidity. Care must be taken to prevent dry sliding within the bearing. Storage facilities must be dry and not
subject to severe variations in temperature or humidity. In good conditions the bearings can be stored for up to one year.
10 Troubleshooting
10.1 Increased Bearing Temperature
Cause : lack of lubrication
Solution : Regularly check the oil level, inspect the bearing surface for score marks. Check that the filter does not restrict oil
flow.
10.2 Excessive scoring of the bearing shell

Cause : Dirt particles in oil
Solution : Change oil (possibly polish out scores on bearing surface). Change oil filter.
11 Ordering Spare Parts

Every bearing has a part and order number embossed onto the manufacturer’s plate. In order to ensure the delivery of the
correct parts please quote these numbers in all correspondence or return the part to Zollern for repair or replacement.
The following parts are supplied as sub-assemblies:
Sub-assembly Position (fig. 1)

Bearing Shell 5.1 to 5.3
Seal carrier Bearing housing (sizes 9-28) : 1.1 & 1.2
Loose oil ring 10
Seal Carrier 15.1
Floating labyrinth seal (machine side) 21.1 & 21.2
Floating labyrinth seal (exterior) 20.1 & 20.2
Bolt on baffle with Teflon bronze strips 25.1
Labyrinth ring N/A
Machine seal with or without Teflon bronze strips (30.1 & 30.2)
Zollern Vertriebs-GmbH + Co.

Werk Herbertingen
-Gleitlagertechnik-
Heustr.1
D-88518 Herbertingen
Tel.: +49.7586.959-0
Fax: +49.7586.959-715
8
Empfehlung für synthetische Recommendation for Synthetic
Schmierstoffe für Gleitlager Lubricants for Sleeve Bearings
Beide Gleitlager der Maschine sind für Both sleeve bearings of the machine are
synthetische Schmierstoffe geeignet. designed for synthetic lubricants.
Gleitlager werden ab Werk ohne Sleeve bearings are delivered without oil
Ölfüllung ausgeliefert und sind mit filling and are protected against
Korrosionsschutz versehen. corrosion by the manufacturer. There is
Korrosionsschutz braucht vor no need to remove the protective coat
Inbetriebnahme nicht entfernt zu before commissioning.
werden.
Als Schmierstoff dürfen nur Use only lubricants according to the

Maschinenöle entsprechend der following list!
nachfolgenden Schmierstoffliste
verwendet werden.
!! Es ist unbedingt auf richtige !! It is most essential to pay

Viskosität, Ölmenge und Öldruck attention to the viscosity, oil quantity
gemäß Maßzeichnung zu achten!! and oil pressure according to the
dimensional drawing!!
Die Lager sollen vor Inbetriebnahme bis The bearings should be filled with oil, up
etwa Mitte des Schauglasses mit Öl to about half of the sight glass prior to
gefüllt sein. commissioning.
Schmierstoffempfehlung: Recommendation:
Shell Corena AS 46 Shell Corena AS 46

Klueber Summit SH 46 Klueber Summit SH 46
Mobil Rarus SHC 1025 Mobil Rarus SHC 1025
Esso und Mobil Lubricants, Hamburg Esso und Mobil Lubricants, Hamburg
www.mobil-oil.com www.mobil-oil.com
Cummins Generator Technologies Cummins Generator Technologies

Germany GmbH Germany GmbH
Bunsenstr. 17 Dreieich branch
85053 INGOLSTADT Benzstr. 47-49
GERMANY 63303 Dreieich
www.cumminsgeneratortechnologies.com Phone: +49(0)841-792-0 GERMANY
info@cumminsgeneratortechnologies.com Fax: +49(0)841-792-250 Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40
Spare Parts
Ersatzteile: 0.2.0 Spare Parts: 0.2.0
1 Dichtungsträger Seal Carrier

2 Labyrinthdichtung mit Wurmfeder (außen) Labyrith seal with Garterspring (outside)
3 Ölablauf Oil Outlet
4 Gehäuse Unterteil Housing Lower Part
5 Gehäuse Oberteil Housing Upper Part
6 Ringschraube Ring Bolt
7 Ölschauglas (Gehäuse Oberteil) Oil inspection glass (upper part of housing)
8 Gleitlagerschalen Sleeve bearing Shells
9 Schmierring Lubrication Ring
10 Labyrinthdichtung mit Wurmfeder (innen) Labyrinth seal with Garterspring (inside)
11 PT 100 PT 100
12 Ölschauglas (Gehäuse Unterteil) Oil inspection glass (lower part of housing)
13 Sichtthermometer Thermometer
14 Kühlschlange Cooling Coil
15 Ölablassschraube Oil drain plug
Cummins Generator Technologies Germany GmbH Cummins Generator Technologies Germany GmbH
Ingolstadt Branch Dreieich Office
Bunsenstraße 17 Benzstraße 47-49
85053 Ingolstadt 63303 Dreieich
Germany Germany
www.cumminsgeneratortechnologies.com Phone: +49(0)841-792-0 Phone: +49(0)6103-5039-0
info@cumminsgeneratortechnologies.com Fax: +49(0)841-792-250 Fax: +49(0)6103-5039-40
Ersatzteile: 1.2.2 Spare Parts: 1.2.2
1 Gleitlager AS Sleeve Bearing DS

2 Lagerschild AS Endshield DS
3 Luftblende AS Air baffle DS
4 Maschinendichtung AS Seal Retainer DS
5 Statorgehäuse Stator housing
6 Maschinendichtung BS Seal Retainer NDS
7 Erreger-Stator Exciter Stator
8 Lagerschild BS Endshield NDS
9 Gleitlager BS Sleeve Bearing NDS
10 Dichtungsträger Seal Carrier
11 Luftblende für Hilfserreger Air baffle for aux. exciter
12 Hilfserregergehäuse Aux. Exciter
13 Hilfserregerstator Aux. exciter stator
14 Montagedeckel für Hilfserreger Service Cover
15 PT100 B-Lagerschild PT100 Endshield NDS
16 Stillstandsheizung Anti Condensation Heater
17 PT100 A-Lagerschild PT100 Endshield DS
18 Bürstenhalter für Rotorerdung Brush holder for Rotor Grounding
19 Kohlen für Rotorerdung Brushes for Rotor Grounding
Germany Germany
Ersatzteile: 3.0.0.1 ms Spare Parts: 3.0.0.1 ms
1 Klemmenkasten Unterteil Terminal Box Lower Part

2 Stromwandler Current transformer
3 Kupferschiene Wandleranschluß Copper Bar Transformer Terminal
4 Kupferschiene Sternpunkt Copper Bar Star Point
5 Kupferschiene U, V, W Copper Bar U, V, W
6 Isolator Insulator
7 Statik Wandler Static Transformer
8 Klemmkasten-Deckel Terminal Box Cover
9 Abschlussplatte Endcover Plate
10 Muffe Oberteil Bushing upper part
11 Muffe Unterteil Bushing Lower Part
12 Anpassungstrafo Potential Transformer
13 Schutzschalter für Anpassungstrafo Security Switch for Potential Transformer
Germany Germany
Ersatzteile: 4.0.0 oRT Spare Parts: 4.0.0 oRT
1 Hilfsklemmenkasten Auxiliary Terminal Box

2 Deckel für Hilfsklemmenkasten Cover Auxiliary Terminal Box
3 Reihenklemmen Terminals in a Row
4 U-Schiene U-Bar
5 Abschlussplatte Gland Plate
Germany Germany
Ersatzteile: 6.0 obi Spare Parts: 6.0 obi
1 Kupferschiene Copper Bar

5 Überspannungsableiter Over Voltage arrestor
6 Kabelbrücke Cable link
7 Rotierende Gleichrichter Rotating Rectifier
8 Halterung Holding device
9 Gleichrichterträger Rectifier Carrier
Germany Germany
Technical Data
page 1 Standard Specification
date: 06.03.2007
file: W20V34-50Hz-11kV-10913kVA.doc
Generator for Wärtsilä engine
W20V34SG
.
MAONA
Type DIG 167 f/8 P/07060
Rated data:
Output/kVA 10.913
Power factor cos ϕ 0,8
Rated voltage/V 11.000
Rated current/A 573
Frequency/Hz 50
Rated speed/rpm 750
Rules and regulations:

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

Circuit diagram no.: K850.3.135
Rated voltage operation range: Between 95 ... 105 % of rated voltage.
Voltage adjustment range +/-5 % of rated voltage for continuous operation
+/- 10 % of rated voltage for short time only resp. for
synchronization
Dynamic voltage variation TVD = - 25 % at sudden full load application at rated PF
TVR = + 28 % at sudden full load shedding at rated PF
Parallel operation Alternator suitable for parallel operation, both with mains and
other alternators. Damper cage and droop transformer are
built-in.
Overload 10 % for 1 h, within 6 hours.
or acc. to IEC 60034, i.e. 50 % for 30 sec.
(see attached overload curve)
Voltage wave form line-line no load: Deviation less than 5 % (IEC 60034)
Single harmonic Less than 2,5 %
Efficiency at 1/4 2/4 3/4 4/4 5/4 load

• cos ϕ = 0,8 95,2 96,9 97,3 97,3 97,3 %
• cos ϕ = 0,9 95,3 97,1 97,6 97,6 97,6 %
• cos ϕ = 1 95,4 97,3 97,8 98,0 98,0 %
Reactances:
• synchronous xd = 198 % (unsaturated)
• transient xd' = 32,5 % (saturated)
• subtransient xd'' = 18,0 % (saturated)
• inverse x2 = 18,9 % (unsaturated)
• zero sequence xo = 5,4 % (unsaturated)
• quadrature axis synchronous xq = 99 % (unsaturated)
• quadrature axis subtransient xq" = 19,8 % (saturated)
• leakage reactance x1s = 14,4 %
• Rated impedance ZN = 11,09 Ω
• short circuit ratio Kc = 0,55 p.u.
date: 06.03.2007
W20V34SG
.
Resistances:
• Stator winding ra (20°C)= 0,0049 p.u. (20°C)
• Main field rf (20°C)= 0,650 Ω (20°C)
Time constants:
• transient no-load Tdo' = 4,00 s
• subtransient no load Tdo” = 36 ms
• transient short circuit Td' = 660 ms
• subtransient short circuit Td'' = 20 ms
• quadrature axis subtransient Tq" = 63 ms
• quadrature axis subtr. no load Tq0" = 200 ms
• anchor / DC Ta = 140 ms
• exciter machine Te = 340 ms
Short circuit data:

• Sustained 3-phase S.S.C. 1,72 kA for 5 s
• Max. peak current 3-phase: 8,10 kA
• Initial short circuit 3-phase 3,18 kA
• Initial SC torque 2-phase: 1003 kNm
• Initial SC torque 3-phase: 772 kNm
Exciter data:
• Field resistance rf (20°C) = 10,3 Ω (20°C)
• Current + voltage no load: if0 = 1,5 A / uf0 = 18 V
• Current + voltage rated load: ifN = 4,4 A / ufN = 52 V
Construction:
• The generators consist of a primary internal pole machine and an external pole exciter.
For power supply to the automatic voltage regulator, the alternators are equipped with an auxiliary
winding.
• Stator:
A welded design is used for the stator housing. The stator core pack consists of hydraulically
pressed, low-loss dynamo laminations. It is pressed together with the housing via pressure plates
to form a compact unit. This ensures a stiff construction appropriate for the special operating
conditions for Diesel generating sets.
The stator winding is insulated in accordance with insulation class F acc. to EN 60034.
The winding heads and wirings are supported by suitable fastening elements and firmly linked
together by mechanical means to guard against electrodynamic loads caused by current forces.
• Rotor:
The rotor consists of the shaft and the main revolving field.
The main revolving field in salient pole design consists of hydraulically pressed lamination sheets
or of steel plates. A damper cage is installed as standard.
The main rotor windings are made of flat copper and are protected against centrifugal forces by
suitable components.
The rotor winding is insulated in acccordance with insulation class F acc. to EN 60034
As standard the rotor is dynamically balanced with half key acc. to EN 60034.
• Bearing plates:
Bearing plates are welded. The alternator feet are integrated in the bearing end housings.
Design details:
Design B 20 / IM1101
Outline drawing no.: AZ 20666 C
Rotor drawing no.: 83602 A
Alternator weight/kg: 32.600
Rotor weight/kg: 13.145
Rotor-moment of inertia (I)/kgm²: 2.424
Prime mover Wärtsilä diesel engine type 20V34SG

Direction of rotation (seen to DE) CCW
Overspeed capability 1,25 x rated speed f. 2 min.
Dynamic balancing: Balancing will be done with half key on shaft end.
date: 06.03.2007
W20V34SG
.
Mounting of coupling halve: A coupling hub, readily machined and balanced, delivered by
Wärtsilä free AvK factory will be mounted on the generator
shaft end after the factory test run.
Terminal box location (seen to DE) On top of NDE bearing shield, connections see circuit diagram
Cable outlet To right hand side (unless otherwise confirmed ) via undrilled
cable gland plates.
Gland plates made of non-magnetic material.
Outlet terminals/pcs. 4
Current transformers: Built-in in terminal box: 2 x 3 pcs. current transformer for
measuring and protection functions. Transformation ratio
600/5/5 A, class 5P10/5P10, 2 x 20 VA.
Voltage transformers: No VTs for external use provided.
Excitation transformers: All VTs and CTs required for proper excitation and regulation
(ABB Unitrol1000) are included in addition to the above
mentioned.
Auxiliary connections: Separate terminal box for low voltage connections
(temperature monitoring, heater, excitation terminals,
regulator), connections see circuit diagram K850.3.135.
Bearings Flanged (bracket mounted) sleeve bearings, self-contained,

with oil-ring lubrication.
Bearing isolated at non-drive end.
Driven end equipped with earthing brush
Enclosure IP 23, acc. to IEC 34 Part 5 (machine)*

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

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

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

Over temperature protection 2 x 3 x PT 100 in stator windings
1 x PT 100 per each bearing
Anti-condensation heater Built-in, connection to 400 V 1~ +/- 10%, 50 Hz,
rated power consumption 1500 W
Droop transf. f. parallel oper. Included
Factory testing Standard works test according Wärtsilä document 4V64L0037

are included and documented for each generator.
Testing in presence of Wärtsilä: Wärtsilä and/or their customer are welcome to witness the
factory test.
date: 06.03.2007
W20V34SG
.
Standard tests are: • Visual inspection (see below “Final check”)
• Measurement of cold resistances
• Residual voltage measuring
• Voltage balance
• Rotating field control / phase sequence check
• Inspection of bearings
• Vibration measurement at no load
• Load characteristic at p.f. = 0,1
• Evaluation of efficiency (single losses method, only for the
1st alternator of each series).
• No load saturation curve (only for the 1st alternator of each
series).
• Short circuit curve (only for the 1st alternator of each
series).
• Adjustment of voltage regulator
• Voltage setting range
• Underspeed protection adjustment
• Parallel operation adjustment
• Sustained SCC
• Overspeed test at 120 % rated speed
• High voltage test
• Measurement of insulation resistance
Final check: General check and test of assembled parts, wiring, labels,
connection diagram, rating, heater, temperature elements etc.
Further tests: More tests like temperature rise measurement, noise testing
etc. can be performed on request.
Painting / surface conservation Standard surface preparation and primer

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

German or English language, consisting of:
• General alternator description
• Description of regulation system
• General outline- and shaft drawings
• Connection diagram with legend
• List of spare parts
• Maintenance instructions
• Factory test reports and, if ordered, certificates of
classification societies.
Extended documentation and/or other languages are possible
at price addition.
Quality assurance Offer, order handling, manufacturing and testing are done
according to ISO 9001. Approval of DNV for ISO 9001 is
available.
Seite 1 Legende zum Schaltbild Nr. Legend to Circuit Diagram No.
Page 1 K 850.3.135 K 850.3.135
B5 Spannungsregler UNITROL 1000 Automatic voltage regulator UNITROL 1000

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

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

(nicht AvK Lieferumfang) 10 A (not AvK supply) 10 A
Erstellt am: 24.11.06 Issued on: 24.11.06
AvK geprüft von: Diegeler Checked by: Diegeler
Revision Nr.: 0 Revision No.: 0
Alternator type: DIG 167 … -8
No load and short circuit characteristic
U/UN - I/IN
1,40
1,30
1,20
1,10
1,00
0,90
0,80
0,70
0,60
0,50
0,40
0,30
0,20
0,10
0,00
0,00 30,00 60,00 90,00 120,00 If [A] 150,00
characteristics valid for type output

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

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

Wälzlager / Gleitla- Roller / Sleeve
85 90 85 90
ger bearing
AvK empfiehlt jedoch generell, bei der Inbetrieb- Generally AvK recommends adjusting the shut
nahme die Abschaltwerte entsprechend den tat- down values by the commissioning according to
sächlichen Gegebenheiten einzustellen. Nach the actual conditions at site. After a test run with
einem Probelauf mit Nennlast über ca. 3-4 Stun- rated load of approx. 3-4 hours the temperature
den sollten die Temperaturfühler mit einem Ab- sensors should be adjusted with a distance of
stand von ca. 5 K zu den gemessenen Werten approx. 5 K to the measured values. By this ad-
eingestellt werden. Zu beachten ist bei dieser justment, the maximum possible cooling air inlet
Vorgangsweise, daß die max. mögliche Kühlluft- temperature should be considered.
eintrittstemperatur berücksichtigt wird.
This is first of all important for the temperature
Dies gilt besonders für die Temperaturüberwa- supervision of roller / sleeve bearings, as a tem-
chung der Wälzlager/Gleitlager, da ein Tempera- perature rise, generally, indicates a bearing dam-
turanstieg normalerweise auf Lagerschäden hin- age. However, this can only be registered when
deutet. Dies kann jedoch nur erfaßt werden, falls the warning and shut down level have been ad-
Warnung- und Abschaltlevel relativ nah auf die justed relatively close to the rated temperatures.
Nenntemperatur eingestellt sind!
For sleeve bearings used witin the generator se-
Abweichend zu o.g. Werten gelten für Gleitlager ries DIG 167 the following alarm and shut down
der Generatorbaureihe DIG 167 die folgenden values must be adjusted.
Werte:
Alternator type Alarm °C Shut down°C
Generatortype Warnung°C Abschaltung°C DIG 167 c/d/e 103 105
DIG 167 c/d/e 103 105 DIG 167 f/g/h/i 107 110
DIG 167 f/g/h/i 107 110
The above given values for alarm and shut down
Diese Warn- und Abschaltwerte können nur durch are only valid, if the synthetic oil listed on the out-
die Verwendung der auf der Maßzeichnung ange- line drawing is used.
gebenen Synthetikölsorte erreicht werden.
Germany Germany
Information zum Explosionsschutzblech Information to explosion protection device
Das Explosionsschutzblech ist ein Schutzsystem The explosion protection device is a protective
zur Druckentlastung, das den Schaden im Falle system for decompression that limits the damage
einer Explosion im Klemmkasten örtlich begrenzt. caused by an explosion in the terminal box and
Eine Explosion kann im Fehlerfall durch einen keeps the effect local. A spark-over in the terminal
Überschlag im Klemmenkasten entstehen. Hierbei box can - in case of an failure - lead to an explo-
werden Luft und andere Materialien, aufgrund der sion. Due to extreme high temperatures, air and
extrem hohen Temperatur, schlagartig um ein other materials expand to a multiple of their nor-
vielfaches des Ausgangsvolumens ausgedehnt. mal volume.
Es wird versucht, den aus dieser Reaktion entste- Pre-determined breaking points are designed for
henden Druck gezielt durch Sollbruchstellen so reducing the occurring pressure so that the con-
abzubauen, dass die Auswirkungen der Explosion sequences of an explosion can be minimized.
minimiert werden kann. Primäres Ziel ist, dass Primary target is to eliminate the risk of danger to
eine Personengefährdung nahezu ausgeschlos- staff and other persons.
sen werden kann.
Zu diesem Zweck wird in die Muffe des Klemm-

kastens konstruktiv eine Sollbruchstelle zur For this purpose a metal plate is integrated in the
Druckentlastung integriert. Diese besteht aus vier terminal box extension duct. This plate consists of
Einzelblechen, die zu einer viereckigen Platte four smaller triangular sheets fixed together by
angeordnet sind. Die Einzelbleche werden in der four welding dots in each corner and one in the
Mitte und in den Ecken von einzelnen Schweiß- middle. Resulting from this assembling the plate
punkten gehalten. Dieser Zusammenbau wird in gets a rectangular shape. This pre-determined
Richtung Generator zeigend montiert, um im Un- breaking point for decompression is positioned
glücksfall, Schaden an vorbeigehenden Personen towards the alternator to ensure that – in case of
abzuwenden und um eventuell auftretenden Split- an explosion - no person is harmed, when walking
terflug zu minimieren. by and to reduce the danger of flying fragments.
Der Schlitz im Explosionsschutzblech wird bei der

Endmontage so abgedichtet, dass die geforderte
Schutzart (IP23, IP54, …) erfüllt, allerdings die The cuts have to be sealed before assembling to
Druckentlastungsfunktion nicht beeinflusst wird. acquire the required protection class (IP 23,
IP54…) without adversely affecting the decom-
Im Falle einer Explosion im pression-function.
Klemmkasten muss unverzüglich
eine Inspektion des gesamten Ge- If case of an explosion in the ter-
nerators erfolgen. minal box, a complete inspection
of the entire generator has to take
Es reicht nicht aus, lediglich das Explosions- place.
schutzblech zu erneuern.
It is not enough just to replace the explosion pro-
tection device.
issued approved
Date 14.02.2008 14.02.2008
Position Mechanical Design Mechanical Design
Engineer Manager
Signature Andreas Bachhuber Thomas Koerner

Fax: +49(0)6103-5039-40
Explosionsschutzblech
Explosion protection device
Explosionsschutzblech
Explosion protection device
must show towards alternator or in any direction, where

sudden release can not cause harmful effects for op-
erators and safety relevant installations

Fax: +49(0)6103-5039-40
t®êíëáä®=cáåä~åÇ=ló=
Doc. id: WDAAA158982 e
Date: 16-Apr-2003
Page: 1 (1)
Status: ISSUED
Made/Approved: KPA008 / KPA008
Name: REFERENCE INFORMATION
Subject: O&M Manuals - QR
SEE QUALITY RECORDS — VOLUME 8
CONSULTE LOS REGISTROS DE CALIDAD — VOLUMEN 8
CONSULTE OS REGISTOS DE QUALIDADE — VOLUME 8
VOIR LES ENREGISTREMENTS DE QUALITE — VOLUME 8
LÁSD MINŐSÉGI FELJEGYZÉSEK — 8. KÖTET
СМ. ОТЧЕТЫ О КОНТРОЛЕ КАЧЕСТВА – ТОМ 8
SIEHE QUALITÄTSPROTOKOLLE – VOLUM 8

____________________________________________________________________________________________________________________________________________________
Klüber Lubrication München KG

ein Unternehmen der Freudenberg-Gruppe
a member of the Freudenberg group Edition: Okt-06
Germany Argentina China, People’s Rep. of
Klüber Lubrication Argentina S.A. Klüber Lubrication China Ltd.
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+593-2-2561177
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Ukraine Dubai/UAE
Singapore, Republic of Evrosmazki +971-4-8815027
Klüber Lubrication South East Asia Pte Ltd Borispolskaja str., 12-B Fax: +971-4-8815036
25 International Business Park 02099 Kiev
# 04-54 German Centre +380-44-5672646
Singapore 128384 Fax: +380-44-5672646
+65-6562-9460 office@evrosmazki.com.ua
Fax: +65-6562-9469
sales@klueber.com.sg United Arab Emirates
REDA INDUSTRIAL MATERIALS LLC
Singapore, Republic of P.O. Box 15004
Marine Teknik Pte. Ltd. Khalid Al Attar Tower, Suite 901
Blk 196, Pandan Loop # 05-17 Sheikh Zayed Road
Pantech Industrial Complex Dubai
Singapore 128384 +971-4-3325100
+65-6779-8366 Fax: +971-4-3325200
Fax: +65-6779-8266
marineteknikpl@pacific.net.sg United Kingdom
Klüber Lubrication Great Britain Ltd.
Slovakia Hough Mills, Northowram
KLH, s.r.o. Halifax, HX3 7BN
Sládkovičova 4 +44-1422-205115
96501 Žiar nad Hronom Fax: +44-1422-206073
+421-45-6722754 sales@uk.klueber.com
Fax: +421-45-6723475
klh@klh.sk
____________________________________________________________________________________________________________________________________________________


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Contents

1 General Notes and Instructions

6 Rotor mounting/dismounting description

Wärtsilä Finland Oy - Power Plants 07/2008

1.1 Important notes for users The technical information

The operating instructions are to be kept Any unauthorized modifications and

Cummins Generator Technologies Germany GmbH Page 2

All rights reserved. Reprints 2.2 Signs on the generator

Machine out of order

This sign is mounted when the installation

ABSTANDSMAß-PROTOKOLL For operating the electrical machine the

2.5 Special Dangers

3. Shipping, Handling, Storage that comply with the local regulations,

Please comply with the local It is not permitted to use

3.4 Unloading the generator

The unloading has to be performed in

Please refer to the freight

3.5 Storage of the generator

After unloading, the

Wrapped parts and assessories must not

The machine and packages have to be

If it is planned to store the

Cummins Generator Technologies Germany GmbH Page 6

Cummins Generator Technologies Germany GmbH

Cummins Generator Technologies Germany GmbH Page 7

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

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

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

Bearing design: Roller bearing

Pos. 1.1 - 1.19

II. Mechanical Inspection

Pos. 2.1 - 2.20

III. Test Run

Pos. 3.1 - 3.14

IV. Maintenance Result

Cummins Generator Technologies Germany GmbH Page 2

a) Location: building marine

b) Atmosperic conditions: dry high humidity

c) Ventilation: unrestricted adequate

a) Site duty: single parallel idle

b) Duty cycle: 24 hours daily occasionally standby

c) Load condition: inductive non linear

d) Operation: manned unmanned

a) Dirt content: slight dust light layer dirt

b) Corrosion: none, very little steel/iron

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

Cummins Generator Technologies Germany GmbH Page 3

1.1 Examination of cable entry and cable shoes

1.2 Examination of strain relief of connecting power cables

1.3 Check of fixation of transformers installed

1.4 Examination of cable entry and cable shoes

1.5 Check of strain relief of connection cables

1.6 Insulation test of stator windings

a) Stator winding phase U against ground

b) Stator winding phase V against ground

c) Stator winding phase W against ground

1.7 Insulation test of stator windings

a) Stator winding phase U against phase V

b) Stator winding phase U against phase W

c) Stator winding phase W against phase V