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Operating instructions

Three-phase synchronous alternators, series DSG 29 ... 99


with "COSIMAT C" or "COSIMAT N" voltage regulator

Before installing and starting up this machine, please read these instructions carefully.
Machine No. _____________________________
Circuit diagram No. _______________________

CONTENTS
1.

Operating and maintenance instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

Checking for damage incurred during transit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2

Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3

Setting up the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4

Cooling the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


1.4.1 Coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.2 Direction of cooling air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.3 Quality of cooling air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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2
2
2
2

1.5

Preparations prior to starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6

Machine drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.1 Belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.2 Coupling drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.3 Aligning the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3
3
3
3

1.7

Changing direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8

Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.9

Starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.9.1 Insulation resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.9.2 Operating speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4
4
5

1.10

Interference suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.11

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.12

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.13

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.13.1 Bearing types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.13.2 Permanently-lubricated bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.13.3 Regreasable bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.13.4 Assembling the bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.13.5 Dismantling the bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.13.6 Monitoring the bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.14

Dust filters and monitoring of thermal behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


1.14.1 Synthetic filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.14.2 Wire mesh filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7
7
7

1.15

Drying out the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


1.15.1 Drying out with integral ventilation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.15.2 Drying out by short-circuiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7
7
7

2.

Faults, causes and remedies for DSG machines with


"COSIMAT C" and "COSIMAT N" voltage regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

3.

Circuit diagram with voltage regulators "COSIMAT C" and "COSIMAT N" . . . . . . . . 10-11
Note: detailed information on the regulator and circuit diagrams is given in the
description and adjusting instructions for "COSIMAT C" and "COSIMAT N".

4.

Spare part drawings and spare part lists DSG 29...99, B20/B14, B16/B5, B16 . . . 12-16

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The relevant machine documents for each order must be entered on the title page of the operating instructions.

1. Operating and maintenance instructions


1.1 Checking for damage incurred during transit
Immediately after receiving the machine, inspect it for damage
incurred during transit. The transport or delivering company
must be notified of possible complaints immediately, or at the
latest within seven days of delivery (covered by warranty).

exhaust gas and heated cooling air cannot be drawn in


by the machine.

1.4 Cooling the machine


1.4.1 Coolant temperature

1.2 Transport
During transit and storage, the machine must not be supported
on the terminal box or air entry hood, or exposed to any
sources of damage.
Store preferably at a constant temperature in a dry, well-ventilated room where the machine will be protected against
sudden impact.
If transported over long distances, it is advisable to protect
the machine against the effects of the weather by sealing it in
a plastic cover together with a quantity of desiccant (moisture
indicator), so that it remains dust-free and air-tight.

The machine is normally built to run at a coolant temperature


of up to 40C and at an installation height of up to 1000
meters above mean sea level. Coolant temperatures higher
than stated on the machines data plate will result in power
loss.
At a coolant temperature of 45C, up to 96 % of the nominal
power can be drawn off; at 50C up to 92.5 % is permissible.
If the machine is ordered to run at coolant temperatures of
higher than 40C, this is shown on its rating plate together
with the alteration in power rating.
1.4.2 Direction of cooling air

Machines with plain or taper roller bearings and machines in


a stored condition are supplied with additional transit protection.
On dual-bearing versions with deep-groove ball bearings, the
bearings are pre-loaded and are supplied without an additional transit keeper.
This transit keeper should never be removed until the machine
has been set up in its future operating position on site.
Install the transit protection again if the machine is, for
instance, to be shipped on or stored as a separate unit after
trials.

The machine is cooled by an integral fan dependent on


the direction of rotation, mounted on the shaft. It draws
cooling air from the non-drive end and expels it at the drive
end.
If it is intended to use forced cooling on special versions, either
alone or to support the integral fan, the direction of airflow
and rotation must be correct here too (see dimensions sheet
for data).

Important:

For transport as a complete machine set, take the necessary


safety precautions, for instance support the machine set on
anti-vibration elements or attach transit keepers.

The distance between the fan inlet or outlet


on the machine and any nearby wall must
not be less than the minimum dimension,
otherwise ventilation will be obstructed.

1.3 Setting up the machine

Minimum distance (guide value):


1 x diameter of machine

The installation site must comply with the machines enclosure


rating and be sufficiently large for cooling and maintenance
purposes.
When setting up the machine, make sure that:

the relevant operation and maintenance safety regulations are observed

cooling air can enter and exit freely

1.4.3 Quality of cooling air


To extend the service life of the machine, and in particular its
windings and bearings, it is extremely important that neither
contaminated nor aggressive cooling air be allowed to enter
it.
An air filter can be installed if requested by the customer, or
can be retrofitted provided sufficient space is available.

1.5 Preparations for starting up

1.6.2 Coupling drive

Pull the protective lacquer coating off the end of the shaft and
the flange, or remove it with solvent. Never clean it off with
emery cloth. Comply with the relevant regulations on environmental protection and safety.

The machine rotor is balanced with a half key. The


grooved drive elements must therefore be balanced on a
smooth mandrel.

There is a threaded hole on the shaft, to which a puller can


be attached for installing and removing discs or couplings.
Hammering is not permitted, as this can damage the bearings.
If the machine is delivered with transit keepers in position,
remove them.
If the machine is of single bearing design, its rotor is delivered
attached to the shaft flange and the housing by a steel hoop
to prevent axial displacement and is located in position
radially between the shaft and fan housing by an angle
bracket. The steel hoop must be removed before assembly.
Make quite sure that the angle bracket and/or any keepers
are removed from the gap only after the rotor has been
centered on the drive shaft flange. Failure to do so can result
in damage to the exciter machine and the B-bearing.

The coupling must be dynamically balanced to an accuracy


of Q 2.5 according to VDI 2060.
The sensitive anti-friction bearings require the couplings, belt
pulleys etc. to be tightened by special devices. If this is not
possible, heat the parts to 80C. They can then be pushed
on easily, provided the bore corresponds to tolerance class
"H". Ensure that the drive elements are securely located after
tightening. They must be securely clamped against their
mechanical stops.
If the hub of the drive elements is shorter than the shaft end,
this difference must be compensated by a spacer bushing to
prevent imbalance and uneven running.
1.6.3 Aligning the machine
Precise, careful alignment of the machine ensures that it runs
with a minimum of vibration, thus extending the service life of
the machine and in particular of the bearings. Only flexible
couplings of low radial rigidity should be used.

1.6 Machine drive


1.6.1 Belt drive

Even slight errors of alignment can rapidly result


in damaged bearings.

If the machine is driven by a belt, the machine must be ordered


specifically with bearings and bearing lubrication to match
the higher loads. Most belt driven machines have roller
bearings on the input side.

It is vital that all the feet are fully in contact. Uneven undersurfaces cause stresses in the bearings and must be compensated
for by attaching sheet metal strips. Once the machine is
aligned correctly, secure it with dowel pins.

The rotor must be ordered with balancing by half key,


and the grooved belt pulley must be dynamically balanced
on a smooth mandrel. The belt must run smoothly, without
jerking.

When aligning a machine of single bearing design which is


not flanged onto the drive motor, it is important to comply with
the reference dimensions specified on the dimension sheet. This will ensure a uniform air gap beneath all
poles and the correct axial position of the rotor.

Desired balancing accuracy: Q 2.5 according to German


VDI 2060 standard.
When flat-type belts or V-belts which have already been in
operation for a fairly long time are removed for maintenance
purposes, they must be replaced by new ones (since they will
have become too hard for re-use).

To prevent damage to the crankshaft or drive motors plain


bearings, it is essential to observe the manufacturers assembly
instructions.

Important:
Belts that are tensioned too tightly can put
the bearings at risk. For this reason, establish the correct belt tension with the belt
manufacturer or the plant that supplied the
machine, and have checks carried out on site.

Possible test method:


Slowly turn the coupling through 360 and
determine maximum deflection of the dial
gauge.
M = dial gauge

Guide values
Shaft center displacement

Shaft tilt

1.7 Changing direction of rotation


The machines fan is of a directional pattern.
Note that the rotary field also changes with a reversal in the
direction of rotation.
If the machine is to be used in parallel operation, the plug
connections for measuring lines U and W on the"COSIMAT C"
and "COSIMAT N" regulator must be changed over. The rotary
field will change at the main terminals.

Coupling gap

Unused cable sockets in the terminal box must be protected


against dust and moisture, and closed so that they cannot turn.
Take up slack at all screw contacts and nuts.
If current surges or vibration are to be expected, secure the
cables with cable clips or racks. If the plant is set up on flexible
mountings, ensure adequate slack in the cables.
1.9 Starting up
1.9.1 Insulation resistance

1.8 Electrical connections


The machine must be connected up according to the accompanying circuit diagram. Installation is permitted by a qualified electrician only.
Comply with the following points:

VDE safety regulations or those of the local safety authorities

Local electricity suppliers guidelines regarding protective


measures

Phase sequence or direction of rotation of machine field


as stated on rating plate.

When connecting the cable, make sure that no mechanical


forces can act on the machines connecting terminals.

After a long period out of use or in storage, the machines


insulation resistance must be measured.
We recommend that the bearings be regreased before the
machine is started up.
Before starting up, measure the insulation resistance of the
winding between phases (if the star point is separate) and
between phase and earth. All parts not subjected to the
measuring voltage must be earthed.
When measuring the insulation resistance, all connections
(main connection, measuring connection and protection or
suppression circuit) must be disconnected from the winding.
The suppression elements and measuring leads must be
disconnected during high-voltage insulation tests and tests with
insulation measuring appliances.

Do not drop below the following specific insulation resistance values (at 25C) on windings that
have been in operation for lengthy periods:

Increased vibration may result from insufficiently accurate


alignment, poorly fitted foundations or frame, or weak mountings.

With nominal voltage < 1000 V


Insulation resistance 0.5 M/kV

1.12 Maintenance

Measurement must be carried out using 500 V direct voltage


or a crank indicator with a direct voltage output. Due to the
capacitive charge in the winding, the measuring unit indicates
the correct insulation resistance value only after several seconds have elapsed.
Earth the winding immediately after the measuring voltage has
been switched off.
If the insulation values are too low, first check the terminal
insulation for dirt and moisture. Clean or dry them as the case
may be, and repeat the measurement. Damp windings can
lead to current leakage, flash-over or breakdown.
If insulation resistance on new, cleaned or repaired windings is less than that stated below,
drying out is needed (see Item 1.15, Drying out
the machine).
On low-voltage machines with a nominal voltage below
<1000 V, insulation resistance should not be less than the
following values:
4 M at a coil temperature of 25C
1.5 M at a coil temperature of 80C
1.9.2 Operating speed
The machines speed must correspond to the value stated on
its rating plate. The machine must run smoothly, both at
no-load and when under load. If the drive machine runs at
reduced speed, the voltage regulators underspeed protection
cuts in and de-excites the machine.
Irregular running will lead to deviations from the nominal
ratings.
The machine is voltage-regulated and maintains a voltage
accurate to 1,5% for the "COSIMAT C" and to 1% for the
"COSIMAT N" in any condition between no load and full
load, even if its speed fluctuates by 5%.
1.10 Interference suppression
The machines comply with radio interference requirement "N"
as stated in German VDE 0875.
Note that the standard of interference suppression is related
to the quality of earthing.
1.11 Operation
During operation, current-conducting and rotating parts must
be sealed with the covers provided for this purpose.

Before starting work on the machine, make sure that it is


switched off and take action to prevent it from being switched
on again. All work must be performed by qualified staff only.
If there is moisture or dust in the terminal box, it must be
removed above all from the surface of the insulating parts.
The reason for the accumulation of moisture or dust must then
be established and rectified.
Brushless machines are maintenance-free apart from their
regreasable bearings and the dust filters, if fitted.
However, make sure that the air inlets and outlets are not
obstructed during operation.
Like any other machine, the alternator should be handled with
care.
1.13 Bearings
1.13.1 Type of bearings
The standard version of the alternator is fitted with deepgroove ball bearings. The A-side has a fixed bearing, the
B-side a floating bearing.
The deep-groove ball bearings are axially pre-loaded in
relation to each other by spring elements; this ensures smoother running and reduces the negative effects of external sources
of vibration on the bearings.
1.13.2 Permanently lubricated bearings
Size 29, 36 and 43 machines are normally fitted with
deep-groove ball bearings acc. to DIN 625, version 2 Z, on
both sides. The bearings are filled with highgrade bearing
grease by the bearing manufacturer and sealed on each side
with two cover plates.
The expected operating life is approx. 25,000 operating
hours at a machine speed of 1500 rpm. The bearings are
lubricated for life. On machines of a single-bearing design,
bearing operating life must be expected to be 30% shorter.
1.13.3 Regreasable bearings
Size 52, 62, 74, 86 and 99 machines with relubricating
devices normally bear a plate on which the following information is stated:

Relubricating interval in hours of operation

Type or specification of anti-friction bearing grease

Before regreasing, clean the nipple so that dirt


cannot enter the bearings.
Using a medium-sized manual grease gun (approx. capacity
500 g), approx. 1 g of grease can be fed in per stroke at
the tapered lubrication nipple (AM 8 x 1 DIN 71427).
Where possible, apply grease when the machine is running,
unless this represents a hazard for the operating personnel.
Regreasing interval
Bearings must be regreased in accordance with the regreasing interval stated on the alternator plate, but at least once
a year.

Initial greasing quantity and regreasing quantity at each


lubrication point in grams (guide values only:)
Size
Initial greasing

1)

Regreasing

52

62

74

86

99

100

150

350

350

450

30

40

70

70

80

1) Amount of grease required when renewing bearings.

Type of anti-friction bearing grease


On delivery, the bearings are lubricated with high-grade,
lithium-soap grease of grade 3 consistency (NLGI-KL anti-friction bearings). The grease channels between the lubricating
nipple and bearings are filled with anti-friction bearing grease
before leaving the factory.

Under adverse operating conditions, e.g. a humid


atmosphere, relatively high dirt accumulations, severe vibrational loadings etc., the regreasing interval must be
reduced accordingly.

Alternatively, the following types of lithium-soap anti-friction


bearing grease can be used:

Reduction factors f1...f3 for adverse operating


and ambient conditions:

Shell Alvania

G3

SKF/Alfalub

LGMT 3

Esso Unirex

N3

Mobil Mobilgrease

532

- Influence of higher bearing temperature

Texaco (DEA)

EP 3

moderate (up to 75C)


high (75...85C)
very high (85...120C)

These greases are of grade 3 consistency and comply with


DIN 51 825.

f3=0.7...0.9
f3=0.4...0.7
f3=0.1...0.4

- Influence of dust and humidity on the bearings active


surfaces
moderate
high

f1=0.7...0.9
f1=0.4...0.7

- Influence of sudden impact, vibration and oscillation


moderate
high
very high

f2=0.7...0.9
f2=0.4...0.7
f2=0.1...0.4

If the permitted coolant temperature is exceeded by app. 15C, the relubricating interval
must be halved.
Relubricating quantity
A- and B-side bearings must each be regreased with the
amount of grease stated.
After about three regreasing operations, remove expelled
grease.
After about five regreasing operations, keep applying more
grease until fresh grease is visible at the outlets. Then run the
machine if possible at half speed for one hour and then at the
nominal speed. Check the temperature of the bearings and
compare with those temperatures obtained before regreasing.

Recommendation:
Always regrease the bearings with the same selected brand
of grease.
1.13.4 Assembling the bearings
Bearings must only be renewed by a qualified
person working in a dust-free environment, on
a clean surface and using clean tools. The grease
and bearings must be kept free of impurities, otherwise they
will wear out faster and possibly even fail. The bearing
components must be arranged as shown in the illustration (see
spare part drawing). The grease regulating disk should be
rigidly attached to the shaft.
When changing bearings, install type-approved bearings
only, and maintain the correct amount of bearing play (usually
"C3").
Do not remove new bearings from their packs until just before
they are installed. Do not wash the bearings, as the anti-corrosion agent applied to them is intended to mix with the similar
agent in the anti-friction bearing grease. Clean the old grease
off the parts of the bearing that are to be re-installed.
When fitting the bearing, heat it to about 80 - 100C in an
oilbath, oven or by an inductive method. Make absolutely sure that it is located centrally and remains
in positive contact with the shaft shoulder.

Once they have cooled down, pack the bearings with


grease.

tions. However, it is often more economical to change the


filter mat.

The inner and outer bearing covers must each be filled with
grease to 2/3 of their full capacity.

1.14.2 Wire mesh filter elements

The initial grease quantity is specified in the table under Item


1.13.3.
1.13.5 Dismantling the bearings
During shaft production, the bearing seat and the bearing
stop shoulder on the shaft are subject to particularly stringent
quality control. This is essential to maintain the accuracy of
shape needed to keep the bearings fully operational.
When dismantling the bearings and bearing rings, it is
therefore important to handle the bearings and bearing rings
with particular care, otherwise the bearing seats on the shaft
could become damaged. Use a puller to remove. Heat the
parts evenly to a temperature of app. 80C all round.
1.13.6 Monitoring the bearings
The first indication of damaged bearings is usually a noticeable change in running behavior, or noise, vibration or
temperature if bearing damage has reached an advanced
stage.

Recommendation:
Monitor the bearings by measuring transmitted noise and
vibration at regular intervals, and compare the readings with
those taken on previous occasions.

These are wet filters and are supplied dry. Before starting up,
apply a thin film of oil or "Viscinol" to the filter plates. Dirty
wire mesh filters should be cleaned using compressed air or
suitable washing agents (soda or "Purinol") and wetted again
when dry.
1.15 Drying out the machine
If the insulation value between the winding and the core or
between windings is less than that stated in Item 1.9.1, the
machine needs drying.
1.15.1 Drying out with integral ventilation system
In many cases it can be dried suitably using its own ventilation
system, but it should not be live while this is being carried out.
On the "COSIMAT C", the plugs should be disconnected at
terminals UH1 and WH1. On the "COSIMAT N" voltage
regulator, the connections UH1-UH1 and WH1-WH1 must
be opened. If no improvement in the insulation resistance is
registered after a running period of app. two hours, the
alternator must be dried out by shorting.
1.15.2 Drying out by short-circuiting
a) Short the main terminals U, V and W via a current
transformer and current meter (for app. 1.2 x nominal
current) while the machine is at a standstill.

1.14 Dust filters and monitoring of thermal behavior

b) Pull off plugs at terminals I1 and K1 as well as UH1


and WH1 on the "COSIMAT C".

To prevent the windings from overheating when the filters are


dirty, three temperature sensors are installed in the stator
winding. Their trip mechanism must be installed in the switch
cabinet.

Open bridges I1-I1 and K1-K1 as well as UH1-UH1


and WH1-WH1 at the "COSIMAT N" voltage regulator.

In addition, probes can be installed to allow the degree of


contamination at the filters to be measured directly. Their trip
mechanism must be installed in the switch cabinet. Cleaning
must be performed at regular intervals even if the machine is
protected against excessive temperatures by integral coil
temperature monitoring devices.
On machines with integral dust filters, please note the following:
1.14.1 Synthetic filter elements
These are dry filters and must be cleaned at regular intervals.
These intervals vary depending on the rate at which dirt
accumulates. Cleaning may be performed using compressed
air, water at temperatures up to 50C, or cleaning fluid.
Comply with the relevant environmental and safety regula-

c) Use a 12 V or 24 V battery and rheostat to feed in exciter


current at terminals I1 and K1 on the "COSIMAT C" or at terminals I1 and K1 on the "COSIMAT N".
Important:
connect the positive pole to I1 and the negative pole to K1.
d) Run the alternator at its nominal speed and adjust
the short circuit current at the rheostat to app. 1.2 x nominal current (see performance data plate).
Continue to dry the machine until its insulation resistance has
risen to a sufficient level. We recommend measuring at
approx. 2-hour intervals.

2. Faults, causes and remedies for DSG alternators


with "COSIMAT C" or "COSIMAT N" voltage regulator
Fault at alternator

Cause

Remedy

1. Voltage too low.

1.1 Input speed too low.

Check whether LED H2 on regulator lights


up. If it does so, then the underspeed protection has tripped; increase the speed until
the LED goes out.

2. Nominal voltage does not respond to ad- 2.1 Setpoint potentiometer is defective.
justment at R1.

Check voltage setpoint potentiometer at terminal s/t for signs of interruption. Rectify
the interruption.

2.2 Sensing leads wrongly connected.

Examine sensing lead connections U, and


W on "COSIMAT C" or U, V and W on
"COSIMAT N". Check whether the machines nominal voltage lies within the rated
voltage range.

3.1 Setpoint potentiometer is defective.

Examine the voltage setpoint potentiometer


for a short circuit. Renew the setpoint potentiometer. Check the potentiometer leads for
a short circuit. Rectify the short circuit.

3.2 A sensing lead is broken.

Rectify the fault.

4.1 Input speed drops under load.

Check the regulator of the drive machine.

4.2 One of the fuses on the cooling body


is defective on the "COSIMAT N".

Check the fuse on the inside of the cooling


body; renew if necessary (10 A super quickacting).

4.3 Rotating diodes are defective.

Check rotating diodes V1 and over-voltage


conductor V3; renew if necessary.

3. Alternator voltage too high, cannot be


brought down by adjustment at R1.

4. Severe voltage collapse when under


load.

5. Alternator does not respond to excitation. 5.1 Input speed too low. Less than 50 % of
nominal speed.

Check the speed regulator of the drive motor. Check the power transmission to the alternator.

5.2 Remanence voltage of auxiliary exciter


is too low (less than 6 % nominal voltage).

Briefly excite the machine by attaching a


4.5 V battery with its positive pole at I1
and negative pole at K1.

5.3 No voltage at auxiliary exciter winding


UH1-UH2 or WH1-WH2.

Check whether windings UH1-UH2 and


WH1-WH2 are interrupted in the stator of
the auxiliary exciter. Rectify the interruption.

5.4 Fault in regulator circuit.

Check whether the external connections on terminals I1, K1 UH1 and WH1 are in place.
On the "COSIMAT N", check the bridges
also.

5.5 Fault at regulator connections.

Check input and output connections of regulator.

5.6 Regulator fuse has blown on


"COSIMAT N".

Check the regulator fuse on the inside of


the cooling body and renew if necessary
(10 A super quick-acting).

5.7 Power stage transistor is defective.

On the "COSIMAT N", replace the regulators power stage.


On the "COSIMAT C", replace the entire regulator.

Cause

Remedy

5.8 Regulator is defective.

Replace the regulator

5.9 Rotating rectifier is defective.

Check rotating diodes V1 and over-voltage


conductor V3; renew if necessary.

6. Oscillating voltage in separate operation.

6.1 I-share too low.

Set switch S1 to a higher number, and


move R1 slightly in a clockwise direction if
necessary.

7. Alternator voltage fluctuates at irregular


intervals.

7.1 Loose contact in one regulator input


lead.

Check the leads that connect the regulator.


Check the connections on the machines terminal board. Re-tighten nuts.

7.2 Blockage at mechanical regulator on


drive machine.

Check the speed regulator on the drive motor. Rectify the fault.

8. Oscillating reactive output in parallel


operation.

8.1 Droop setting is too low.

Move R7 slightly in a clockwise direction.

8.2 I-share too low.

Set switch S1 to a higher number.

9. Excessively high reactive current output


in parallel operation.

9.1 Droop setting is too low.

Move R7 slightly in a clockwise direction.

9.2 Transformer connections k/l are incorrect, e.g. bridged by switch.

Open the bridge.

9.3 Are the secondary connections at terminals k/l correct or not?

Swap over the k/l connections, "k" must be


the white lead.

9.4 Droop transformer not installed in phase "V".

Install droop transformer in phase "V", check


direction of rotation.

9.5 If "COSIMAT C" is installed separately,


sensing leads U/W may be wrongly positioned (U/V/W on "COSIMAT N").

Check the sensing lead. There must be a


right-handed field on "COSIMAT N".

10. Excessively low reactive current output


in parallel operation.

10.1 Droop setting is too high.

Move R7 slightly in an anti-clockwise direction.

11. Active load not equally distributed.

11.1 This is affected by the drive machine


only, i.e. determined by the drive machine
regulator. The alternators regulator affects
only the reactive output and therefore the
distribution of the reactive load (see 8., 9.
and 10).

Check the drive motor (regulator, fuel supply etc.).

Fault at alternator

Please contact our Service Department if you have any problems. Our experienced specialists
will be glad to help you. If possible, inform us of your findings by telefax or telephone.

3. Circuit diagrams

U1
W2

V1

W1
C1
V2

U2

*R1

*T6
Stator

G1

Rotor

s
t
U 500
U 250
W
l
k
I1

G2

G1

V3 V1

R3
R4
R1
S1
R7
R6

COSIMAT C

3.1 Circuit diagram for DSG 29 and 36 with "COSIMAT C" voltage regulator (No. Z 2811.001)

K1
UH1
UH2/VH1
WH1
WH2 U1

G2

G3

Stator

H1
H2

*E

T1

Wicklung
winding

Linkslauf: Meleitungen U-W tauschen


counter-clockwise rotation:
sensing lines exchange U-W

*U4

T2

G1 Hauptmaschine
main machine
G2 Erregermaschine
exciter machine
G3 Hilfswicklung
auxiliary winding
V1 rot.Gleichrichter
rotating rectifiers
V3 berspannungsableiter
over-voltage suppressor
*T6 Statikwandler
droop transformer
U1 Spannungsregler / A.V.R.
R3 >f-Einstellung />f-adjust.
R4 Spannung Sollwert
voltage adjustment
R1 Anpassung / gain
S1 Stabilitt / stability
R7 Statik % / droop %
R6 I-Messung / I-sensing
*R1 Sollwerteinsteller
voltage setting rheostat
C1 Entstrkondensatoren
interference capacitors
*E Stillstandsheizung
anti condensation heater
Kaltleiter f.Temp.-berwachg.
PTC for temperat.monitoring
*U4 Temp.-Auslsegert(extern)
over temp.relay(extern)
*= nur auf Bestellung
only upon order

*R1

C1

*T6
Stator

G1

Rotor

Stator

G2

G1

V3 V1

10

R3
R4
R1
S1
R7
R6

K1
UH1
UH2/VH1
WH1
WH2 U1

G3
*E

Wicklung
winding

G2

s
t
U 500
U 250
W
l
k
I1

COSIMAT C

3.2 Circuit diagram for DSG 43 with "COSIMAT C" voltage regulator (No. Z 2811.003)

H1
H2
T1
*U4
T2

Linkslauf: Meleitungen U-W tauschen


counter-clockwise rotation:
sensing lines exchange U-W

G1 Hauptmaschine
main machine
G2 Erregermaschine
exciter machine
G3 Hilfswicklung
auxiliary winding
V1 rot.Gleichrichter
rotating rectifiers
V3 berspannungsableiter
over-voltage suppressor
*T6 Statikwandler
droop transformer
U1 Spannungsregler / A.V.R.
R3 >f-Einstellung />f-adjust.
R4 Spannung Sollwert
voltage adjustment
R1 Anpassung / gain
S1 Stabilitt / stability
R7 Statik % / droop %
R6 I-Messung / I-sensing
*R1 Sollwerteinsteller
voltage setting rheostat
C1 Entstrkondensatoren
interference capacitors
*E Stillstandsheizung
anti condensation heater
Kaltleiter f.Temp.-berwachg.
PTC for temperat.monitoring
*U4 Temp.-Auslsegert(extern)
over temp.relay(extern)
*= nur auf Bestellung
only upon order

3.3 Circuit diagram for DSG 43...99 with "COSIMAT N" voltage regulator (No. Z 2817.001)

R1

250-500V

C1

s
t
U
U
W
l
k
I1
I1'
K1'
K1

T6
G1

Stator

R2

G2
F1

Rotor
Stator

G1

V3 V1
G3
*E

Wicklung
winding

G2

11 12i 12k

21 22i 22k
H1
H2
T1
T2

*U4

U/F

90-250V

R3
R4
R1
S1
R7
UH1 R6
UH1'
UH2
n
VH1
WH1 M/m
WH1'
N
WH2 U1

COSIMAT N

Schnellentregung: Verbindung UH1-UH1',


WH1-WH1'entfernen
quick de-excitation:
open connection
UH1-UH1';WH1-WH1'
Linkslauf: Meleitungen U-W tauschen
counter-clockwise rotation:
sensing lines exchange U-W

G1 Hauptmaschine
main machine
G2 Erregermaschine
exciter machine
G3 Hilfswicklung
auxiliary winding
V1 rot.Gleichrichter
rotating rectifiers
V3 berspannungsableiter
over-voltage suppressor
T6 Statikwandler
droop transformer
U1 Spannungsregler / A.V.R.
R3 >f-Einstellung />f-adjust.
R4 Spannung Sollwert
voltage adjustment
R1 Anpassung / gain
S1 Stabilitt / stability
R7 Statik % / droop %
R6 I-Messung / I-sensing
R1 Sollwerteinsteller
voltage setting rheostat
R2 Vorwid.(nur bei Bedarf)
series resistor(if requd.)
C1 Entstrkondensatoren
interference capacitors
*E Stillstandsheizung
anti condensation heater
Kaltleiter f.Temp.-berwachg.
PTC for temperat.monitoring
*U4 Temp.-Auslsegert(extern)
over temp.relay(extern)
F1 Schutzschalter
protective switch
*= nur auf Bestellung
only upon order

11

4. Spare part lists


4.1 Spare part drawing No. EZ 29...52, B20/B14
01.24
01.01
01.02

01.21

01.23

01.01

01.07

01.05

01.07
01.05

01.02
01.25
01.03

01.22

01.03

01.06
01.17
01.16
01.15
01.14

Nachschmierung
Relubricated
04.01

02.02

01.04

02.01

01.13
01.12

01.11

01.10

01.06

Dauergeschmiert
Permanently lubricated

03.01
05.01
05.02
02.03

01.09

02.04
02.05

02.06
05.03

04.02

Spare part list No. EL 29...52, B20/B14


Item 01
01.01
01.02
01.03
01.04
01.05
01.06
01.07

Assembly
A-side inside bearing cover
A-side bearing
A-side retaining ring
Air guide nozzle
B-side bearing
B-side retaining ring
Coil springs

Quantity
1
1
1
1
1
1
12

01.09
01.10
01.11
01.12
01.13
01.14
01.15
01.16
01.17
01.21
01.22
01.23
01.24
01.25

Fitted key for shaft end


Terminal box
Terminal box lid
Terminals
Auxiliary terminals
Voltage regulator
Auxiliary electr. modules
Droop transformer
Suppression kit (capacitors)
Inside bearing cover B-side
Grease regulating disc B-side
Outside bearing cover B-side
Outside bearing cover A-side
Grease regulating disc A-side

1
1
1
1
*
1
*
*
1
1
1
1
1
1

Item 02
02.01
02.02
02.03
02.04
02.05
02.06

Rotor
Rotor complete/balanced
Fan (note direction of rotation)
Exciter rotor, wound
Rotor rectifier, complete
Varistor
Spacer pins, per alternator

Item 03 Stator
03.01
Stator, complete, with feet

Item 04 A-side bearing plate


04.01
A-side bearing plate
04.02
Protective grille

1
2

Item 05
05.01
05.02
05.03

1
1
1

B-side bearing plate


B-side bearing plate
Exciter stator, wound
Cover

* Quantity varies depending on machine version.

When ordering spare parts, always state the machine number!

12

Quantity
1
1
1
1
1
2+3

4.2 Spare part drawing No. EZ 29...52, B16/B5


01.21
01.23
01.02

01.02

01.22

01.03

01.03

01.17
01.16
01.15
01.14

Nachschmierung
Relubricated

02.02

01.01

02.01

01.13
01.12

01.11

01.10

Dauergeschmiert
Permanently lubricated

03.01
05.01

01.04

05.02
01.06

02.03

01.07

02.04
02.05

01.05
02.06
01.08
05.03
01.09

Spare part list No. EL 29...52, B16/B5


Item 01
01.01
01.02
01.03
01.04
01.05
01.06
01.07
01.08
01.09
01.10
01.11
01.12
01.13
01.14
01.15
01.16
01.17
01.21
01.22
01.23

Assembly
Air guide nozzle
B-side bearing
B-side retaining ring
Flange (B16)
Coupling hub (complete on rotor)
Coupling plates (SAE)
Thrust ring
Retaining screws
Protective grille
Terminal box
Terminal box lid
Terminals
Auxiliary terminals
Voltage regulator
Auxiliary electr. modules
Droop transformer
Suppression kit (capacitors)
Inside bearing cover B-side
Grease regulating disc B-side
Outside bearing cover B-side

Quantity
1
1
1
1
1
*
1
*
1
1
1
1
*
1
*
*
1
1
1
1

Item 02
02.01
02.02
02.03
02.04
02.05
02.06

Rotor
Rotor complete/balanced
Fan (note direction of rotation)
Exciter rotor, wound
Rotor rectifier, complete
Varistor
Spacer pins, per alternator

Quantity
1
1
1
1
1
2+3

Item 03 Stator
03.01
Stator, complete, with feet

Item 05
05.01
05.02
05.03

1
1
1

B-side bearing plate


B-side bearing plate
Exciter stator, wound
Cover

* Quantity varies depending on machine version.

When ordering spare parts, always state the machine number!

13

4.3 Spare part drawing No. EZ 62...99, B20/B14


01.24

01.23

01.01

01.21

01.02

01.05

01.25

01.22

01.18
01.17

01.03

01.12

01.07

01.06
01.11

01.10

01.20
02.02

01.04

02.01

01.19

03.01

01.16
05.02

05.01

04.01

01.15
01.14
01.13

02.03
01.09

02.06

02.05
02.04

05.04

05.04a
05.05

04.02

Spare part list No. EL 62...99, B20/B14


Item 01
01.01
01.02
01.03
01.04
01.05
01.06
01.07

Assembly
A-side inside bearing cover
A-side bearing
A-side retaining ring
Air guide nozzle
B-side bearing
B-side retaining ring
Coil springs

Quantity
1
1
1
1
1
*
12

01.09
01.10
01.11
01.12
01.13
01.14
01.15
01.16
01.17
01.18
01.19
01.20
01.21
01.22
01.23
01.24
01.25

Fitted key for shaft end


Terminal box
Terminal box lid
Terminals
Auxiliary terminals
Voltage regulator
Auxiliary electr. modules
Droop transformer
Suppression kit (capacitors)
Differetial protection transformers
Connection joint
Cable gland plate
Inside bearing cover B-side
Grease regulating disc B-side
Outside bearing cover B-side
Outside bearing cover A-side
Grease regulating disc A-side

1
1
1
1
*
1
*
*
1
*
1
1
1
1
1
1
1

Item 02
02.01
02.02
02.03
02.04
02.05
02.06

Rotor
Rotor complete/balanced
Fan (note direction of rotation)
Exciter rotor, wound
Rotor rectifier, complete
Varistor
Rectifier plate

Item 03 Stator
03.01
Stator, complete, with feet

Item 04 A-side bearing plate


04.01
A-side bearing plate
04.02
Protective grille

1
2

Item 05
05.01
05.02
05.04.
05.04.a
05.05

1
1
1
1
1

B-side bearing plate


B-side bearing plate
Exciter stator, wound
Rear end shutter
Side shutter
Cover (regulator)

* Quantity varies depending on machine version.

When ordering spare parts, always state the machine number!

14

Quantity
1
1
1
1
1
1

4.4 Spare part drawing No. EZ 62...99, B16/B5


01.23

01.21

01.02

01.22

01.18
01.17
02.02

01.01

02.01

03.01

01.12

01.03
01.11

01.10

01.20
01.19
01.16
05.02

05.01

01.04

01.15
01.14
01.13

01.06
02.03
01.07

02.06

01.08

02.05

01.08a

02.04

01.05

05.04

05.04a
05.05

01.09

Spare part list No. EL 62...99, B16/B5


Item 01
01.01
01.02
01.03
01.04
01.05
01.06
01.07
01.08
01.08.a
01.09
01.10
01.11
01.12
01.13
01.14
01.15
01.16
01.17
01.18
01.19
01.20
01.21
01.22
01.23

Assembly
Air guide nozzle
B-side bearing
B-side retaining ring
Flange (B16)
Coupling hub (complete on rotor)
Coupling plates (SAE)
Thrust ring
Retaining screws
clamb sleeve
Protective grille
Terminal box
Terminal box lid
Terminals
Auxiliary terminals
Voltage regulator
Auxiliary electr. modules
Droop transformer
Suppression kit (capacitors)
Differetial protection transformers
Connection joint
Cable gland plate
Inside bearing cover B-side
Grease regulating disc B-side
Outside bearing cover B-side

Quantity
1
1
1
1
1
*
1
*
*
1
1
1
1
*
1
*
*
1
*
1
1
1
1
1

Item 02
02.01
02.02
02.03
02.04
02.05
02.06

Rotor
Rotor complete/balanced
Fan (note direction of rotation)
Exciter rotor, wound
Rotor rectifier, complete
Varistor
Rectifier plate

Quantity
1
1
1
1
1
1

Item 03 Stator
03.01
Stator, complete, with feet

Item 05
05.01
05.02
05.04.
05.04.a
05.05

1
1
1
1
1

B-side bearing plate


B-side bearing plate
Exciter stator, wound
Rear end shutter
Side shutter
Cover (regulator)

* Quantity varies depending on machine version.

When ordering spare parts, always state the machine number!

15

4.5 Spare part drawing No. EZ 62...99, B16


01.23

01.21

01.21

01.22

01.02

01.24

01.23

01.24

01.02

01.03

01.22

01.02a
01.18

01.03

01.17
01.12

Rollenlager
Roller bearing

01.11

01.10

Kugellager
Ball bearing

01.20
01.19

02.02

01.01

02.01

03.01

05.02
05.06

01.04

01.16
05.01

01.15
01.14
01.13

01.05

01.06

02.03

02.06

02.05
02.04

05.04

05.04a
05.05

01.09

Spare part list No. EL 62...99, B16


Item 01
01.01
01.02
01.02a
01.03
01.04
01.05
01.06
01.09
01.10
01.11
01.12
01.13
01.14
01.15
01.16
01.17
01.18
01.19
01.20
01.21
01.22
01.23
01.24

Assembly
Air guide nozzle
B-side bearing
Roller bearing internal ring
B-side retaining ring
Fan housing
Cover / splitted
Flange shaft (B 16)
Protective grille
Terminal box
Terminal box lid
Terminals
Auxiliary terminals
Voltage regulator
Auxiliary electr. modules
Droop transformer
Suppression kit (capacitors)
Differetial protection transformers
Connection joint
Cable gland plate
Inside bearing cover B-side
Grease regulating disc B-side
Outside bearing cover B-side
Bearing cover bolts

Quantity
1
1
1
1
1
1
1
1
1
1
1
*
1
*
*
1
*
1
1
1
1
1
4

Item 02
02.01
02.02
02.03
02.04
02.05
02.06

Rotor
Rotor complete/balanced
Fan (note direction of rotation)
Exciter rotor, wound
Rotor rectifier, complete
Varistor
Rectifier plate

Item 03 Stator
03.01
Stator, complete, with feet

Item 05
05.01
05.02
05.04.
05.04.a
05.05
05.06

1
1
1
1
1
8

B-side bearing plate


B-side bearing plate
Exciter stator, wound
Rear end shutter
Side shutter
Cover (regulator)
Bolts

* Quantity varies depending on machine version.

When ordering spare parts, always state the machine number!


S ub j ec t t o t ec h ni c a l m od i f ic a t i on s wi t ho ut n ot i c e.

16

Quantity
1
1
1
1
1
1

Sales:
AvK Deutschland GmbH & Co. KG
Dreieich branch
Benzstrae 47-49
63303 Dreieich (Germany)
Phone +49 (0) 61 03/50 39-0
Fax +49 (0) 61 03/50 39-40
e-mail: infoavkdr@newage-avkseg.com
http://www.newage-avkseg.com

BV DSG 29-99 -10297 E

AvK Deutschland GmbH & Co. KG


Bunsenstrae 17
85053 Ingolstadt (Germany)
Phone +49 (0)8 41/7 92-0
Fax +49 (0)8 41/7 92-2 50
e-mail: infoavkin@newage-avkseg.com
http://www.newage-avkseg.com