Regulator- operating instructions - emri.nl · PDF fileRegulator- operating instructions . ... these generators have dangerous rotating and non-insulated voltage- ... are equipped

ANHALTISCHEELEKTROMOTORENWERK

DESSAU GMBH

KAD 30161/E Edition 04/2010

Read through before initial operation and store carefully for later reference!

Regulator- operating instructions

for brushless three-phase synchronous generators with regulator types

R10-K, R10-KA, R10-KC, R10-KF

AEM Anhaltische Elektromotorenwerk Dessau GmbH Daheimstr. 18 D - 06842 Dessau - Roßlau After-sales service Tel.: +49 (0) 340 203 304 / 305 Fax: +49 (0) 340 203 311 e–mail: [email protected] homepage: www.aemdessau.de

ANHALTISCHE ELEKTROMOTORENWERK DESSAU GMBH

Page 2 of 24 AEM 30161 – 04/2010

General safety instructions

Notes for use The notes used in the operating instructions have the following significance:

Danger! Is used for activities that may cause considerable personal or material damage. Please read and observe these notes carefully and act particularly cautiously in these cases. Make other users aware of these notes concerning work safety.

ATTENTION! Concerns the observation of regulations, notes or the correct sequence of working

steps to avoid damaging or destroying the generator, its parts and/or parts of the equipment.

NOTE General type of notes ______________________________________________________________________________________

General safety instructions Electrical generators for which these operating instructions were written are designed for use in commer-cial installations. During operation, these generators have dangerous rotating and non-insulated voltage-carrying parts. Serious personal and material damage may be caused by improper use, impermissible re-moval of covers and protective installations, wrong handling and insufficient maintenance. All work to be carried out on electrical generators such as assembly, connection or maintenance must only be carried out while the system carries no voltage and is out of operation. Protect the system against unintended reactivation. These generators must only be transported, put up, connected, put into operation, maintained and operated by specialized staff being trained to observe the relevant safety and installation regulations. All processes must be checked by responsible specialized staff. These specialized staff must have been authorized for their activities by the security system officer (for specialized staff regulations see DIN EN 50110-1 / DIN IEC 60364). Operation by non-qualified staff is prohibited! The person responsible for the installation must make sure • to have safety and operating instructions available and observing them; • to have all safety installations and personal safety equipment available; • that safety installations and personal safety equipment are used; • regulatory maintenance work is carried out; • the maintenance staff is immediately informed or the generator stopped if abnormal voltages, increased

temperatures, oscillations, noises etc. occur so that causes can be determined and damages avoided. The manufacturer's liability is only maintained if the operating instructions are being observed at any time!


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Table of contents 1 Description of exciter system ...................................................................................................................... 4

1.1 Exciter system ...................................................................................................................................... 4 1.2 Voltage regulator .................................................................................................................................. 5

2 Behaviour during operation and notes on use ............................................................................................ 6 2.1 Excitation, de-excitation ....................................................................................................................... 6 2.2 Setting range for voltages, set-point adjuster ...................................................................................... 7 2.3 Voltage response ................................................................................................................................. 7 2.4 Radio interference suppression ........................................................................................................... 7 2.5 Operation .............................................................................................................................................. 8

2.5.1 Overload resistance ...................................................................................................................... 8 2.5.2 Operation with different temperatures of the cooling agent .......................................................... 8 2.5.3 Operation at power factors p.f. < 0.8 ............................................................................................ 8 2.5.4 Underspeed .................................................................................................................................. 8

2.6 Short-circuit response .......................................................................................................................... 8 2.7 Single operation ................................................................................................................................... 8 2.8 Parallel operation ................................................................................................................................. 8

2.8.1 Practical applications .................................................................................................................... 8 2.8.2 Neutral earthing current ................................................................................................................ 9 2.8.3 Synchronization ............................................................................................................................ 9 2.8.4 Parallel operation with static ......................................................................................................... 9 2.8.5 Parallel operation with compensating line .................................................................................. 10 2.8.6 Parallel network operation .......................................................................................................... 11 2.8.7 Electronic voltage adjustment ..................................................................................................... 11

2.9 Emergency operation without regulator ............................................................................................. 11 3 Power factor – regulation .......................................................................................................................... 11

3.1 General information ............................................................................................................................ 11 3.2 Description of functions ...................................................................................................................... 12

3.2.1 Function ...................................................................................................................................... 12 3.2.2 Modifications ............................................................................................................................... 12

3.3 Behaviour during operation and connecting instructions ................................................................... 12 3.3.1 No-load speed behaviour ............................................................................................................ 12 3.3.2 Behaviour under load .................................................................................................................. 12

3.4 Connecting instructions ...................................................................................................................... 13 3.5 Setting instructions ............................................................................................................................. 17 3.6 Adjustment at first startup .................................................................................................................. 18 3.7 Safety instructions for network breakdowns and isolated operation .................................................. 18 3.8 Notes on changing the p.f.-regulator .................................................................................................. 18

4 V/f-control .................................................................................................................................................. 18 4.1 V/f-control ........................................................................................................................................... 18 4.2 Setting instructions of regulator R10-KF ............................................................................................ 19 4.3 R10-KFG adjusting notes ................................................................................................................... 20

5 Troubleshooting ......................................................................................................................................... 20 5.1 Voltage problems ............................................................................................................................... 20 5.2 Checking and replacing the rectifier diode ......................................................................................... 21 5.3 Testing varistors ................................................................................................................................. 21 5.4 Replacing the regulator ...................................................................................................................... 21 5.5 Problems overview ............................................................................................................................. 21 5.6 Troubleshooting for p.f.-regulator R10-KC ......................................................................................... 24


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1 Description of exciter system

1.1 Exciter system

Construction The exciter system consists essentially of the following assembly groups: • choke [6] • current transformer [7] • stationary rectifier stack [8] with step-down resistor • electronic voltage regulator [9]

1 Stator winding 2 Rotor winding 3 Rotor winding of excitation machine 4 Stator winding of excitation machine 5 Rotating rectifier stack 6 Choke 7 Current transformer 8 Stationary rectifier stack 9 Electronic voltage regulator R10-Kx 10 Step-down resistance 11 Static current transformer A Potentiometer voltage B Potentiometer static C Potentiometer stability D External potentiometer voltage

Figure 1: Basic circuit diagram for R10-Kx

All units are installed on a panel on the N side end shield. Exciter system and rotating rectifier stack can be accessed by taking off the hood and opening the clamps or the screw connection. For generator voltages higher 1 kV, an additional transformer with a secondary voltage of 400 V built in to separate the AVR from the high-voltage side. The AVR is in a separate connection box. The exciter unit is protected against unauthorized changes.

Working principle The remanent voltage produced in the stator winding [1] of the generator causes a small current to flow through the stator winding [4] of the exciter via choke [6] and rectifier stack [8] thus setting off self-excitation. The choke [6] limits the exciter current of the exciter. The exact value depends on the air gap between core and yoke of the choke. The required air gap is adjusted by adding insulating material. NOTE For generator voltages higher 1 kV, an additional auxiliary winding is built in into the stator.

The voltage of this auxiliary winding serves as remanent voltage and supply the choke. The load current flows through the current transformer [7]. When load is put on the generator, the secon-dary current of the current transformer [7] is added to the choke current. After rectification in the stationary rectifier stack [8] – a six-pulse bridge circuit – this alternating exciter current flows to the stator winding [4] of the exciter. In order to protect the diodes against voltage surges, both the stationary rectifier stack [8] and the rotating rectifier stack [5] are equipped with varistors. Choke current and secondary current of the current transformer are adjusted such as to permanently main-


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tain a generator voltage of approx. 10 % above the rated generator voltage while the generator rotates at its rated speed and the voltage regulator is disconnected. Every time the rated generator voltage is exceeded, the voltage regulator (AVR) [9] periodically switches on step-down resistor that is located in parallel to the stator winding of the exciter [4]. This ensures that the teminal voltage of the generator is kept at the value set by the set-point adjuster. NOTE The chosen tappings of the winding to choke and current transformer have been optimally

adjusted to the generator in the manufacturer's test shop. You should therefore always con-tact the manufacturer prior to making any changes.

1.2 Voltage regulator

Design The voltage regulator is located in a sealed casing protected against dust and dirt. The casings contains the potentiometers for setting the various regulator functions. The potentiometers are equipped with a self-locking multi-speed mandrel drive that is secured against over-speed by a sliding clutch. The setting range is approximately ± 10 revolutions. The following regulator types are used: R10-K Standard type providing voltage regulation and staticization for parallel operation. Designed with

smoothing capacitor CK and varistor.

R10-KAx In addition to the functions of the R10-K, also contains an analogue input via which the setpoint voltage can be changed within a range of ± 10 % via an analogue signal input, either as 0 – 10 V signal (R10-KAU) or 4 – 20 mA signal (R10-KAI).

R10-KC In addition to the R10-K functions, this type contains a p.f.-regulation part. It can be used either as a staticizing regulator or as a p.f.-regulator. Modifications of regulator R10-KC see section 3. “Power factor – regulation”

R10-KF/ R10-KFG

In addition to the functions of the R10-K, also contains a secondary frequency-dependent volt-age regulation.

NOTE The previously used regulator type R10 was functionally identical with the type R10-K but has no capacitor CK or varistor. It can be replaced without exception by the other type; leave terminal 12 unoccupied in this case.

All R10 series regulators have the same dimensions.

Connections The voltage regulator is connected via spring-loaded terminal strips. The generator voltage is connected as in figure 2 and the enclosed circuit diagram.

Figure 2: Connection for measuring and voltage supply

NOTE For generator voltages between 500 V and 1000 V, the regulator is connected to tappings of the stator winding at approx. 400 V. For generator voltages higher 1 kV the AVR is con-nected to a special measuring transformer (400 V).


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NOTE For current readings a static current transformer in phase W is used. Only some of the paral-lel winding branches of the stator winding are put through the converter. (observe when disassembling the exciter)

The connection of static current transformer to AVR have to be followed according to figure 3 under consid-eration of section 2.7 and 2.8.

Figure 3: Connection for static current transformer For all other connections see the circuit diagram of the generator.

2 Behaviour during operation and notes on use

Danger! Only trained specialized staff are allowed to change settings using a suitable tool. Observe during all setting and other work to be carried out on exciter and regulator that all components carry network potential.

2.1 Excitation, de-excitation

Excitation Self-excitation is provided by the remanent voltage.

Danger! Measure the generator voltage during the excitation process. Remove the external voltage source immediately, when the generator voltage rises. Danger of inverse voltage!

If self-excitation of the generator does not work, excitation can be induced by briefly applying an external voltage (6 or 12 V battery) to terminals X100:3 (battery plus), :4 (battery minus) in the terminal box of the generator (figure 4).

Figure 4: Generator excitation and de-excitation circuit

De-excitation

Danger! After de-excitation and while the drive is running, there is a residual voltage of up to 10 % of the network voltage on the generator terminals. Special notice for generators with voltage more than 1 kV.


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Use a contactor or suitable switch to produce a short-circuit between terminals X100:3 and :4. Current load on the contacts is < 10 A (figure 4).

2.2 Setting range for voltages, set-point adjuster Use the "Spannung" potentiometer of the regulator or an external set-point adjuster to set the terminal volt-age in a range of approx. ± 5 % of the rated value.

Danger! Incorporate the external set-point adjuster in the protective measures against high contact voltage.

You may connect an external set-point adjuster to terminals 6 and 8 on the regulator resp. X100:1 and X100:2 in the terminal box of the generator (rotary resistor 2.5 kΩ (to 5 kΩ admissible), load limit approx. 1 W, test voltage > 2000 V). On the regulator, put jumper 7 - 8 to 6 - 7.

Figure 5: Connection for external set-point adjuster Legend: Regler - Regulator Spannung - Voltage Statik - Static Stabilität - Stability NOTE We recommend using shielded cables!

Put the jumper back to connect 7 - 8 if you are working without external set-point adjuster.

2.3 Voltage response

Static voltage response The voltage regulator maintains the set terminal voltage between no-load and rated current for power factors in a range of p.f. = 0.5 (over-excited) to 1.0 with a tolerance value of under ± 1 %. This constant voltage works for operation without staticization only. Valid speed increases of the generator drive are up to 105 % of the rated speed between rated output and no-load operation.

Dynamic voltage response Adding a rated load of a power factor of p.f. = 0.8 causes a voltage drop by approx. 12 to 15 %. Regulation compensation takes about 0.3 to 0.5 sec. Both nominal values depend on the generator output and its num-ber of poles. Greater additional loads are possible. However, in this case the voltage drops by up to 30 %. Please contact the manufacturer for further information.

Voltage stability The regulator is delivered with optimal settings for static and dynamic voltage response. If the output voltage oscillates, slowly turn potentiometer "Stabilität" (figure 5) clockwise until the output voltage is stable again.

2.4 Radio interference suppression Radio interference suppression corresponds to DIN EN 61000-6-4 unless any other arrangements were made with the manufacturer.


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2.5 Operation

2.5.1 Overload resistance Valid current overloads of the generator at p.f. = 0.5 are 10 % for an hour (once within 6 hours) or 50 % for 2 minutes. Brief overloads at motor starting operations are admissible. During overload conditions, the volt-age tolerance of ± 1 % is no longer valid.

2.5.2 Operation with different temperatures of the cooling agent The rated output stated on the type label is only valid in conjunction with the stated temperature of the cool-ing agent. For other temperatures, the following output changes apply:

T / °C 30 35 40 45 50 55 60 PS / PN 1.06 1.03 1.00 0.96 0.92 0.88 0.84

ATTENTION! Operation in ambient temperatures above 60 °C require manufacturer approval.

2.5.3 Operation at power factors p.f. < 0.8 For power factors p.f.< 0.8, the generator power must be reduced in relation to the power factor.

p.f. 0.7 0.6 0.5 0.4 0.0 PS / PN 0.94 0.89 0.85 0.82 0.80

2.5.4 Underspeed Particular protection of the generator, the exciter or the regulator against underspeed of the generator drive (e.g. during warm-up) is not required. Voltages are maintained constant down to speeds of approx. 90 % of the rated speed. Below this value, the voltage is reduced approximately proportionally to the speed so that every speed is admissible in no-load without time limitation.

2.6 Short-circuit response The current surge (15 - 21 x IN) occurring during short-circuit conditions goes down to the sustained short-circuit current after about 60 to 100 ms. Stable sustained short-circuit current of up to three times the rated generator current is guaranteed for up to 5 sec. Please refer to the data sheet of the generator for all other values. The sustained short-circuit current on one pole is approx. 5 - 6 x IN.

2.7 Single operation To ensure single operation, the static current transformer can be deactivated by putting in a jumper between terminals 4 - 5 (figure 3). This guarantees optimally constant voltage values for the generator. NOTE Single operation is possible without limitations if there is no jumper between 4 and 5 (pa-

rallel operation circuit). In this case, voltage tolerances are determined by the static setting and they are above 2 %.

2.8 Parallel operation

2.8.1 Practical applications Brushless generators are designed for parallel operation. They are equipped with damper winding, connec-tion for compensator circuit, static device and set-point voltage adjuster. The following variations of parallel operation are possible:

• Parallel operation with static with other generators as long as these provide parallel operation features and if practically the same static voltage curves with falling characteristics can be set for all generators;

• Parallel operation with compensator circuits of generators of the same type; • Parallel network operation either with regulator R10-K and non-regulated power factor or using regula-

tor R10-KC with power factor regulation.

For parallel operation of several generators, reactive power distribution as well as current and power output variations must be within the range of applicable regulations. Prerequisites for this kind of operation are that generator drives, and their speed governors in particular, are designed correspondingly providing the same P range (speed drop between no-load and full load operation) or that a active power distribution proportional to the power output is ensured by an automatic active power distribution installation.


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Measure Effect during single operation

Main effect during parallel operation

Voltage set point of generator Generator voltage Generator supply more reactive power

Generator static ----------- Voltage set point of generator Generator voltage

Generator supply less reactive power Generator static ----------- Speed set point of drive Frequency Generator supply more active power Speed set point of drive Frequency Generator supply less active power

NOTE Wrong distribution of active power (kW indicator not proportional to power output) is always caused by the speed regulation of the generator drives. Wrong distribution of reactive current (kW distribution o.k., different current distribution) is caused by the voltage and static settings of the regulator.

2.8.2 Neutral earthing current Connecting the generator star point to the star points of generators of another type or to the network earthed neutral can cause compensation currents of mainly three times the network frequency to flow in the neutral earth conductor that have been caused by different voltage curve lines of generators and mains network. Neutral currents of up to 40 % of the rated current are admissible unless other values have been defined. Reducing the neutral current can be achieved by inserting a special type of choke coil in the switching circuit (please contact the manufacturer).

2.8.3 Synchronization The generators can be synchronized by manual synchronization, automatically quick synchronization or startup synchronization (please contact the manufacturer).

The following prerequisites must be observed for synchronization processes: • almost identical frequency of the two voltage systems Δf ≤ 0.2 Hz • almost identical terminal voltage of generator and mains network, admissible difference < 6 % • identical phase sequence of the two voltage systems • closing of switching contacts at a phase angle of < 15 degrees in relation to the zero crossover of the dif-

ference voltage of the two voltage systems.

ATTENTION! Wrong synchronization causes extremely high electrical and mechanical loads on the generator which must be avoided under all circumstances.

Manual synchronization Use the set-point adjuster to set the generator voltage to the network voltage. After setting smallest fre-quency and phase differences possible by means of a synchronoscope, the generator can be switched on. To avoid the occurrence of inverse power after switching on the generator, the generator frequency should be about 0.2Hz above the network frequency.

Quick synchronization Use an electronic synchronization device to adjust the system to smallest possible voltage, frequency and phase differences automatically. The generator will be switched on considering that time element (switch) is in zero crossover range of the difference voltage.

2.8.4 Parallel operation with static ATTENTION! Check whether the jumper between terminals 4 and 5 of the regulator have been re-

moved. Depending on current and power factor, the generator voltage characteristics have a decline. The voltage drop can be set by the "Statik" potentiometer on the regulator (max. 8 % at p.f. = 0) (figure 5). The voltage drop is increased by turning the potentiometer clockwise. In the factory, the static is set to approx. 2 % (in relation to no-load voltage) at rated current and a power fac-tor of p.f. = 0.8. Constant voltage during parallel operation depends on the static setting. If static setting and static characteristics are nearly the same, the reactive power (in relation to the rated power of the corre-sponding generator) is distributed proportionally.

ATTENTION! Make sure to do a generator adjustment before starting operation. Only specialized staff must do these steps. Check whether all drives have the same percentage value for speed drop between id-le speed and full speed while in single operation. Use the set-point adjuster to adjust the equal values of no-load voltages (±1 V) at all


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generators. For this setting please use the same meter. Put rated load at rated power factor on the generators in single operation possible and check whether an almost identical voltage drop can be observed for all generators.

If you find larger differences, the static potentiometer must be readjusted. Static values of 2 – 3 % at rated power and rated power factor are sufficient for stable parallel operation. This test must not be made with just using active power as this renders the static inefficient. NOTE Proceed as follows to make a supplementary test if only active power operation is possible

when changing the setting: 1. Connect the blue cable from phase U to W and the brown cable from phase V to phase

U on the choke terminal strip [6.1]. 2. Put load on the generators. 3. The voltage drop corresponds to static setting at p.f. = 0.5 and normal switching condi-

tions. 4. While corrections of the static adjustment using the equivalent circuit is to be noted that

the static adjustment is made with p.f. = 0.5. The static adjustment will be accordingly smaller with p.f. = 0.8 therefore.

5. Reconnect all devices after the setup procedure.

Figure 6: Terminal connection for static setting at active power

2.8.5 Parallel operation with compensating line Generators with the same exciter voltage can work in parallel if there is a compensating line (figure 7). NOTE Put in jumper 4 - 5 on the voltage regulator. Compensation for static potentiometer is not required. The compensating line is connected to terminals X100:3 and :4 in the terminal box (make sure to connect only terminals of the same polarity). The max. com-pensating current is 2 A. Provide auxiliary contacts on the generator power on / off switch to ensure that the compensating line is only active during parallel operation. Under proportional active load distribution condi-tions, the compensating line ensures an almost automatically proportional reactive load distribution. ATTENTION! The open-circuit voltages of the generators must be checked and adjusted at no-load

speed of the drives prior to putting a system into operation. In order to avoid measuring errors, measurements must be made with the same device.

The difference between the individual open-circuit voltages of the generators must be no greater than 0.5 %.

Figure 7: Parallel operation with compensating line


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NOTE The starting synchronization can carry out with any numbers of generators in switching

method “compensating line”.

2.8.6 Parallel network operation A prerequisite for parallel operation of an electric device in a fixed network is that overload conditions in vary-ing network situations are avoided. On the active load side this is ensured by a speed regulator or an elec-tronic load distribution. On the reactive load side, this condition must be ensured by implementing a load-dependent modification of the internal generator voltage. This generator voltage adjustment can be realized either by the static device or by a regulation that depends on the power factor (p.f.-regulation). The static device lowers the generator voltage if the reactive power increases. Greater static causes small current changes if the network voltage changes. A special regulator is required for generators with p.f.-regulation, which keeps the adjustable power factor constant independent of the mains voltage (see section 3. p.f.-regulation). NOTE During synchronisation the generator voltage should be approx 1 % higher than the network

voltage in order to avoid under-excited operation with generator reactive current absorption from the mains.

ATTENTION! Observe the neutral earthing current described in section 2.8.2 and the synchroniza-tion conditions in section 2.8.3.

2.8.7 Electronic voltage adjustment In conjunction with the analogue input for the electronic voltage adjustment of regulator R10-KA and R10-KCA, the electronic voltage adjuster ESA1 can automatically adjust the generator voltage to the mains voltage before synchronisation (necessary to contact manufacturer).

2.9 Emergency operation without regulator If the voltage regulator is defect and if no supplementary regulator is available, it is possible to go into emer-gency mode. To do so, simply disconnect connections 1, 2 (resp. 3), 10. ATTENTION! Attach and insulate cable ends. Connect an adjustable resistor of approx. 100 Ω and a load resistance of approx. 2 A to terminals X100:3, :4 in the generator terminal box. The resistor can be used to set the rated generator voltage while the generator is in no-load.

Danger! The resistor is under network potential and must therefore be protected against con-tact.

The voltage can be kept in the required range by readjustment under load. The voltage tolerance value is approx. –5 % without readjustment.

3 Power factor – regulation

3.1 General information There is the option of equipping synchronous generators with a p.f.-regulator to ensure optimal use in paral-lel operation. The manufacturer uses regulators R10-KC for different modifications. These operating instructions provide you with special information about functions, settings and troubleshoot-ing for operating the p.f.-regulator. The enclosed circuit diagram is the basis for all work to be carried out. ATTENTION! Complete generator operation and maintenance requires reference to the mounting

and operating Instructions for S, SE and SEH series brushless three-phase synchro-nous generators.

Danger! Work must be carried out by qualified specialized staff only. The safety instructions given in the mounting and operating instructions for three-phase synchronous generators must be observed at all times and for all works to be carried out on the regulator. Changing settings while the generator is running requires utmost care because of the presence of rotating and voltage-carrying parts.


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3.2 Description of functions

3.2.1 Function Regulator R10-KC extends regulator type R10-K by the p.f. -regulator component. NOTE If you do not activate the p.f.-part (see 3.4 Connecting instructions) you can use regulator

R10-KC like the standard regulator R10-K Use regulator R10-KC to regulate the generator output factor in network environments which are static to a certain degree independently of the active load in a range of approx. 0.6 inductive (over-excited) to p.f.=1.0 (active load only) in a current range between approx. 10 and 100 %. The set value is maintained with a pre-cision of ± 0.05. Under-exited operation is not permitted. To increase stability and to avoid fast responses to short voltage changes (e.g. when the load is increased), the regulator responds with a certain delay. This time constant can be set in a range between 2 and 10 seconds. NOTE The p.f -regulation only refers to the generator (see documentation of generator).

Contact the manufacturer if you want to regulate power factor at the power feeding point.

3.2.2 Modifications Several modifications of regulator R10-KC will be delivered for special connection requirements.

R10-KC In this regulator the setpoint voltage is set within a range of ± 10 % at the regulator internal potentiometer The voltage can be set too within a range of ± 5 % via an external potenti-ometer as 5 kΩ. An external adjustment of the power factor at this regulator is not possible.

R10-KCAx In this regulator the setpoint voltage is set as at the regulator R10-KC. This voltage can be changed within a range of ± 10 % via an analogue signal input, either as 0 - 10 V signal (R10-KCAU) or 4 - 20 mA signal (R10-KCAI).

Optionally, regulator R10-KC can be delivered with supplemental connecting terminals for external p.f.-setting.

R10-KCEXT Adjustment of power factor will be realized via external potentiometer (in panel, control station and others). An adjustment of power factor direct on regulator is not possible.

R10-KCEXTAx Adjustment of power factor will be realized via external potentiometer (in panel, control station and others). An adjustment of power factor direct on regulator is not possible. In this regulator the setpoint voltage is set as at the regulator R10-KC. This voltage can be changed within a range of ± 10 % via an analogue signal input, either as 0 - 10 V signal (R10-KCEXTAU) or 4 - 20 mA signal (R10-KCEXTAI).

R10-KCUEXT Adjustment of power factor and voltage will be realized at this regulator only with external potentiometers. The setting range of voltage is ± 10 %. An adjustment of power factor and voltage direct on regulator is not possible.

3.3 Behaviour during operation and connecting instructions

3.3.1 No-load speed behaviour While in no-load speed, the generator is voltage-controlled even if it is in "Power factor regulation" mode be-cause the transformer [11] provides no signal. Use the "Spannung" potentiometer to set the no-load speed voltage. Synchronization can be made as usual.

3.3.2 Behaviour under load In the very small power output range there is no real practical necessity for exact power factor regulation. To avoid malfunctions in this range, a mechanism inside the regulator automatically switches into power factor regulation mode only if the current has arrived at approx. 10 % of the rated generator current. This condition is indicated by the LED on the regulator lighting up. After synchronization and until the switchover current has been reached, the regulator works in static mode. The power factor in this range can differ from a preset power factor. ATTENTION! Operating the generator at full load with a power factor < 0.8 is not allowed.

Use the following table to reduce the power :

p.f. 0.7 0.6 0.5 0.4 0

P / PN 0.94 0.89 0.85 0.82 0.80


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3.4 Connecting instructions All modifications of regulator R10-KC are regarding to external connection only. Function of modifications is equivalent.

Danger! Incorporate the external set-point adjuster in the protective measures against high contact voltage.

NOTE Connection diagram has to be considered before connection. If there are no external connections, p.f.-regulator R10-KC works as voltage regulator (observe during tests). p.f. -regulation is activated by putting in a jumper between terminals X100:5 and :6 (inside the terminal box) or regulator terminals 9 to 11 resp. if the regulator is connected externally (terminals 4 and 5 without jumper). The connection between X100:5 and :6 resp. the terminals 9 – 11 for external arrangement of regu-lator must be set as contact on the switching panel via the generator switch and must be interlocked with the network coupling switch for safety reasons (see figure 8).

Figure 8: Connection of p.f.-regulator R10-KC Legend: Regler - Regulator T cos - T p.f. cos phi - p.f. Spannung - Voltage Statik - Static Stabilität - Stability


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R10-KCAx The analogue signal for voltage adjustment is connected via the additional terminals 13 and

14 on the regulator .

Figure 9: Connection of p.f.-regulator R10-KCAx

Input R10-KCAI: 4 – 20 mA DC R10-KCAU: 0 – 10 V DC Legend: Regler - Regulator T cos - T p.f. cos phi - p.f. Spannung - Voltage Statik - Static Stabilität - Stability


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R10-KCEXT Connection of potentiometer for power factor adjustment (resistance 5 kΩ, load value 1 W)

will be realized via shielded cable to terminals C1, C2, C3 of regulator.

Figure 10: Connection of p.f.-regulator R10-KCEXT

Legend: Regler - Regulator T cos - T p.f. Spannung - Voltage Stabilität - Stability Statik - Static


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R10-KCEXTAx Connection of potentiometer for power factor adjustment (resistance 5 kΩ, load value 1 W)

will be realized via shielded cable to terminals C1, C2, C3 of regulator. The analogue signal for voltage adjustment is connected via the additional terminals 13 and 14 on the regulator.

Figure 11: Connection of p.f.-regulator R10-KCEXTAx

Input R10-KCEXTAI: 4 – 20 mA DC R10-KCEXTAU: 0 – 10 V DC Legend: Regler - Regulator T cos - T p.f. Spannung - Voltage Stabilität - Stability Statik - Static


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R10-KCUEXT Connection of potentiometers (per resistance 5 kΩ, load value 1 W) will be realized via

shielded cable to terminals C1, C2, C3 for power factor adjustment and to terminals U4, U5, U6 of regulator for voltage adjustment.

Figure 12: Connection of p.f.-regulator R10-KCUEXT

Legend: Regler - Regulator T cos - T p.f. Statik - Static Stabilität - Stability

3.5 Setting instructions The potentiometers (figure 8 - 12) are equipped with self-locking multi-geared spindle drives. A sliding clutch protects them against overturning.

Danger! Observe the safety instructions when working at the generator in operation.

Potentiometer “cos phi” • Turning right (clockwise) reduces the reactive current delivered down to under-excited operation at

approx. p.f. = 0.9 capacitive. • Turning left (anti-clockwise) increases the reactive current delivered (over-excitation up to approx.

p.f. = 0.6 inductive). When changing the setting, please take into account that time constant "T cos” causes a delay of at least 2 seconds between making the change and taking effect.

Potentiometer "T cos” of the p.f.−regulation Setting the time constant for the p.f.-regulation in a wide range allows you to adapt the generator to your in-dividual operating conditions. Turning right increases regulation time. Longer regulation times have a stabiliz-ing effect on oscillating loads.


Page 18 of 24 AEM 30161 – 04/2010

External potentiometers for adjustment of p.f. and/or voltage These potentiometers have to be adjusted before putting into operation to avoid uncontrollable operating condition. For that purpose the 5 kΩ − potentiometers have to be adjusted in a ratio of 1.5 to 3.5 kΩ . The exact adjustment has to be realized in accordance with section 6 afterwards when putting into operation.

3.6 Adjustment at first startup Generator and drive system have to be adjusted to the network when putting them into operation for the first time.

• The right power factor setting is defined by the planned transmission budget for the mains network. Use the "Voltage" set-point adjuster to set the generator voltage to the normal local network voltage. First startup is to be made with the value set in the factory. Should you notice irregular power characteristics during load tapping, turn the time constant towards the "higher" marking.

• If irregular current flows occur when switching from static to p.f.-operations (at approx. 10 % of the rated generator current), turn the static resistor in the regulator towards the "max." marking.

• If voltages are irregular during isolated operation, turn the "Stabilität" potentiometer towards the "max." marking.

3.7 Safety instructions for network breakdowns and isolated operation If the network voltage breaks down while in network parallel operation, the generator must be immediately set to "Voltage regulation" mode (open connection between X100:5 and :6 resp. 9 - 11) and switched off im-mediately or be unloaded by suitable switching sequences. ATTENTION! Generators must not be operated with p.f.-regulation in an isolated network because

this may lead to dangers for the network consumers. If there is no danger of overload, an uninterrupted supply of the isolated network system is possible. Switch-ing over to voltage regulation mode must be ensured by the network interconnecting switch. If there is not switchover to voltage regulation, generator regulation of the p.f. would lead to a voltage in-crease (p.f. set too high) or a voltage decrease (p.f. set too low) in the network. Power factor regulation after re-establishment of network stability must only be activated after synchronization with the mains network.

3.8 Notes on changing the p.f.-regulator After replacing a regulator of series R10-KC the basic setting for network operation must be carried out when putting into service the replacement regulator:

• Connect the regulator according to the circuit diagram, taking care to strictly adhere to the given cable connections.

• Start up the generator until the rated frequency is reached and adjust the generator voltage to the net-work voltage at the voltage potentiometer.

• Synchronise the generator to the network and load with an output of less than 10 %. - The red pilot lamp on the regulator must not light up. - The generator runs in static mode, p.f. regulation is inactive. - Use the “Statik” potentiometer to inductively set p.f. to approx 0.95.

• Load the generator so that the pilot lamp uniformly lights up without flickering (at least 30 % of the rated power).

• Use the p.f. potentiometer to adjust to the required power factor. • If current pulsation occurs (red lamp flickers) within the area of the internal changeover to p.f. regulation,

use the “Statik” potentiometer to increase the static by turning to the right.

4 V/f-control

4.1 V/f-control In specific application cases, e.g. throwing on consumers being large relative to output of driving machine (mainly cases of engines with turbochargers) or operation of isolated networks (marine service) with slip fre-quency, voltage may be controlled as a function of frequency. Generator voltage drop occurs below a certain break frequency. Voltage is frequency-independent above this value (see figure 14 an 15). When load is thrown onto a diesel generating set, a short generator voltage breakdown (some 0.2 to 0.5 sec-onds) and engine speed reduction occur for physical reasons. Since the correction time of voltage is much smaller than the speed correction time (the approximate ratio is 1:10), the town-on electric load virtually re-


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mains constant without influencing voltage whereas the counter moment of motor is supplementary increased by speed reduction. On the other side, frequency-dependent voltage control relieves the motor in the correction phase and reduces the correction time. The diagram in figure 13 shows the moment gradient at different voltage drop levels.

ΔV Voltage drop during load thrown-on (%)

MX Moment based on thrown-on load PX at VN, nN (fN)

(100 - ΔV)² 100 - Δn = M

MX

Admissable to GL code: ΔV = 15% Δn = 10%

Δn Speed reduction in the event of load thrown-on (%)

M Effective moment M MX

Δn / %

1,5

1,0

0

ΔV Δn

1,1

1,0

0,9

0,8

105 0

Figure 13: Relative moment loading

Note Operation 20 up to 70 Hz is possible with a generator of special design and the modification of regulator R10-KFG.

4.2 Setting instructions of regulator R10-KF The regulator R10-KF permits frequency-proportional voltage control in the range between 40 and 59 Hz and has two potentiometers on its operation panel for setting of frequency-dependent control (see figure 14).

fKnick This potentiometer permits setting of the break point below which voltage drop shall occur. This setting is possible in the range between 40 and 59 Hz. A LED is provided and lights as soon as break frequency falls below the limit. For setting, the motor speed shall be changed until the desired value is reached and the po-tentiometer be turned until the LED lights. Manufacturer's setting is 48.5 Hz for 50 Hz service and 58 Hz for 60 Hz service, if not otherwise defined.

U/f (V/f) This potentiometer is used to set the steepness of voltage drop below the break frequency. The range up to ΔU/Δn = 2 may be set. The manufacturer setting is a ratio of 1, i.e. 1 % of speed (frequency) drop corre-sponds to 1 % of voltage drop (for instance, on the 400 V generator the voltage is lowered by 8 V per 1 Hz of frequency reduction).

Figure 14: Voltage-Frequency-Characteristic and description of potentiometers of V/f-regulator R10-KF

Legend: Regler - Regulator Stabilität - Stability Spannung - Voltage Statik - Static


Page 20 of 24 AEM 30161 – 04/2010

4.3 R10-KFG adjusting notes The R10-KFG regulator in conjunction with the compounding system of the SE generator series permits fre-quency-proportional voltage control within the range of approx. 20 to 70 Hz through a special regulator struc-ture and design of the input stage. The voltage tolerance is approx. ± 5 %. Prerequisite is that the drive motor can be set within the relevant speed limits and the compounding system including exciter is specially dimensioned for this purpose. The lowering of the generator’s voltage takes place below an adjustable break frequency. Above this value the voltage is frequency independent (see figure 15). For setting the frequency-dependent control, the R10-KFG regulator has two potentiometers (see figure 3). The adjustment is made as for the R10-KF regulator. NOTE The additional potentiometer UKnick serves only for the adjustment in the electronics test facil-

ity. Attention: Do not adjust!

fKnick and U/f (V/f) The adjustment will be done delivery according to customer arrangement.

Figure 15: Voltage-Frequency-Characteristic and description of potentiometers of V/f-regulator R10-KFG

Legend: Regler - Regulator Stabilität - Stability Spannung - Voltage UKnick - Vbreak Statik - Static

5 Troubleshooting ATTENTION! Immediately switch off the drive if a failure occurs. Carefully inspect the generator while in a voltage-free condition.

Danger! While measuring or setting parameters with the generator running, you must be aware of the fact that all unprotected terminals may carry very dangerous voltages and that they are in immediate proximity to rotating parts. The generator must therefore be locked to avoid contact by unauthorized persons.

ATTENTION! Check-ups of exchanging of parts must only be carried out by trained specialized staff in accordance with IEC 60364 observing all applicable regulations of health care, safety at work and fire protection.

The references to components correspond to figure 1.

5.1 Voltage problems If the generator produces no voltage or unusual voltages, try to find the problem in the exciter, unless a wind-ing has given up. The first step always is to check all connections and cables in the terminal box and on the exciter components for proper connections and safe contacts. ATTENTION! Use the circuit diagram for troubleshooting. Observe wire numbers and colours.


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5.2 Checking and replacing the rectifier diode The test is made with a continuity check instrument with a test voltage > 1 V. The diodes must forward the current in one direction and not do so in the other direction. Minimal values for replacing of the rectifier modules:

Type Forward current IFAV Peak reverse voltage URRM

Stationary rectifier stack [8] 25 / 08 10 A 600 V

Rotating rectifier stack [5] 81 / 08 81 / 14

80 A 80 A

800 V 1400 V

Proceed as follows to carry out the check: • Disconnect all poles of the unit prior to starting the check. • Carefully pull off the flat-cable plugs. • Check the through-state. Stationary rectifier stack [8]

Reverse the polarity of the continuity test instru-ment for testing diodes 4, 5 and 6 (fig. 16).

Rotating rectifier stack [5]

The modules are standard components used by most manufacturers. Observe the electrical min. values when replacing a module. Make sure not to exceed the following torques when reassembling (figure 17): Screws: 5 Nm Terminals: 3 Nm

Figure 16: Test instrument setting for stationary rectifier

Figure 17: Test instrument setting for rotating rectifier

5.3 Testing varistors The test is made as described for the diodes, the difference being that varistors must cut off in both direc-tions. If any current is forwarded, the varistor is defect and needs to be replaced.

5.4 Replacing the regulator Unscrew the 4 attachment screws and disconnect the wires. Replacing the unit is then possible without any problems. Use a pen or screw drive to open the terminals so that you can take out and disconnect the wires. ATTENTION! Carefully observe the terminal assignment plan. Wrong connections damage the gen-

erator. NOTE The system may have to be readjusted (voltage, static, stability) after replacing the regulator.

5.5 Problems overview ATTENTION! For generator voltages < 1 kV measure the remanent voltage on the main terminals

only! For generator voltages > 1 kV measure the remanent voltage on the terminals of auxil-iary winding terminal X 020. For safety reasons, you must interrupt the connection between stationary rectifier [8] and stator winding [4] of the exciter before measuring the remanent voltage. Do not touch voltage-carrying parts, as the remanent voltage is usually in the range between approx. 5 to 10 % of the rated voltage.


Page 22 of 24 AEM 30161 – 04/2010

Problem: Generator voltage too low and not adjustable during operation

Action Consequence Cause of failure, further actions

• Deactivate regulator • Disconnect conductor from

terminal 10 (insulate) and run generator at rated speed

Generator voltage is approx. 1.1 x UN

• Regulator problem • Replace regulator or go into emergency opera-

tion mode (section 2.9) Generator voltage does not change

• Check rectifier stacks [5] and [8] (section 5.2) • Replace if defect

Problem: No generator excitation at no-load speed ATTENTION! Measure the generator voltage before trying to find the problem.

Action Consequence Cause of failure, further actions

Connect battery "+" pole to X100:3 and "-" pole to :4

No generator exci-tation

• Check stationary rectifier [8] (section 5.2) • Replace if defect • Check rotating diodes [5] and varistor [S1] • Replace if defect Check current forwarding of rot. exciter winding [2] on "+" and "-" bar of the rot. exciter [5] • Check current forwarding of exciter winding [4] of

the exciter • To do so disconnect wire 3 from X100:3, :4 and

measure between X100:3 - :4 Generator excita-tion to rated volt-age

• Remanent voltage was too low • Immediately disconnect battery

Without battery support voltage breakdown of gen-erator voltage

• Check stat. rectifier [8] (section 5.2) • Replace if defect Check current forwarding of choke [6] between UVW and XYZ

Problem: Generator voltage too high or too low when putting into operation

Action Consequence Cause of failure, further actions Check speed of drive system

Modify voltage set point Voltage o.k. Voltage setting range insufficient

Check connection of external set-point adjuster Check jumpers 6 - 7 on the regulator (figure 5)

Problem: Generator voltage drops considerably under load

Action Consequence Cause of failure, further actions Check speed of drive system Adjust speed regulator Check rectifier stacks [5] and [8] (section 5.2)

Replace defect elements

Check transformer [7] and cable 2

• Hand in to service if winding damaged • Repair connections

Check static settings: put in jumper between 4 and 5 and put load on generator

Generator voltage must remain con-stant

Remove jumper for parallel operation and readjust "Statik" potentiometer


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Problem: Wrong current distribution in parallel operation

Action Consequence Cause of failure, further actions Check connection of transfor-mer [11] and direction of rota-tion (figure 3)

Remove jumper between 4 and 5 on the regulator if it is in Connect up properly

Measure transformer current under load Current = 0 A Replace transformer [11]

Check performance-dependent distribution of active load

Readjust speed regulator

Check setting of no-load volt-age of all generators (section 2.8.4)

Use "Spannung" potentiometer or external set-point adjuster to adjust no-load voltage

Check whether static setting is even

• Use "Statik" potentiometer to readjust generator • Observe in any case: if one generator accepts

too much reactive power during parallel operation with static and increasing load, then you must in-crease its static setting or reduce that of the other generators (do not fall below about 2 % at rated current and p.f. = 0.8)! (section 2.8.4)

For operation with compensat-ing line: check the connection between generator terminal X100:3 - :4 and compensating line

Check switch contact

Problem: Irregular generator voltage

Action Consequence Cause of failure, further actions Check speed of drive system Adjust speed regulator

Change "Stabilität" potentiome-ter of the regulator

Voltage continues to be irregular

• Regulator defect • Replace regulator • Loose terminal • Check connections

Problem: Generator voltage too high and not adjustable during operation

Action Consequence Cause of failure, further actions Check connection of external set-point adjuster

Check function of step-down resistor R31

Generator voltage is approx. 1.1 x UN

• Step-down resistor R31 or connections defect • Replace resistor, repair line

Generator voltage does not change

• Regulator problem • Replace reg. or go into emergency operation

mode (section 2.9)

• Check air gap of choke [6] • Yoke and shims must be

firmly attached

If the yoke is loose, set the air gap such that the sys-tems sets itself to approx. 1.1 x UN at rated speed and without voltage regulator (disconnect line from terminal 10 and insulate)

Problem: Generator voltage rises under load

Action Consequence Cause of failure, further actions Check connection of tranformer [11] and direction of rotation (figure 3)

Connect-up properly


Page 24 of 24 AEM 30161 – 04/2010

5.6 Troubleshooting for p.f.-regulator R10-KC The Mounting and Operating Instructions for Brushless Three-Phase Synchronous Generators including all instructions for troubleshooting contained therein applies to generators with p.f.-regulator also. When using the p.f.-regulator, also observe the following additional information:

Problem: Regulator does not go into p.f.-operation (LED does not light up) when on load

Action Consequence Cause of problem, further actions Check jumper between 4 and 5 Is not clamped Remove jumper Check contact between terminals X100:5 to :6

Does not close properly Make contact

Check load current Current below 10 % of rated current

Increase load so that the regulator internally activates p.f.-regulation

Problem: Considerable current increase when going into p.f.-operation (up to rated current or more)

Action Consequence Cause of problem, further actions Check direction of rotation and com-pare to information on rating plate

Check connections of transformer [11] and of direction of current flow K – L according to circuit diagram

Replace transformer connections k – l at the regulator (terminals 4 - 5)

Problem: Irregular current when going into p.f.-operation

Action Consequence Cause of problem, further actions Increase static value via "Statik" po-tentiometer (turn clockwise)

Problem: Irregular voltage and / or current during p.f.- operation

Action Consequence Cause of problem, further actions Increase time constant via "T cos” potentiometer (turn clockwise)

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