Instruction Book

No.S4106001 2105

INSTALLATION, OPERATION & MAINTENANCE

INSTRUCTION BOOK

The equipment described in this manual was supplied to:

Ruston Gas Turbines Ltd. for. Hamilton Brothers Oil & Gas Ltd.
for Argyll/Duncan F.P.F.

on Order No.97087

Correspondence relating to the equipment should quote the

GEC Large Machines Limited reference:

The following information should also be given:

Machine

(a) Serial number

(b) Frame size

These two items are given on the machine rating plate and
in the Technical Data section of this manual.

0
GEC Large Machines Limited
Mill Road, RUGBY
Warwickshire, ENGLAND
CV21 1BD
Though the instructions and information given in this book are as
explicit as is practical , expertise is still required to install
and maintain machines . If trouble- free service is to be obtained,
the machines and any auxiliary drive must be installed, set and
checked correctly even though , in some cases , they may have been
supplied fully assembled.

For the erection and commissioning of the equipment supplied, the

services of GEC Large Machines Limited outside construction staff
are strongly recommended ; they have special knowledge of design
details and of suitable erection and checking techniques.

THE HEALTH AND SAFETY AT WORK ACT 1974

The Purchaser should comply with the instructions and

information in this manual , and is strongly advised that
all personnel to be associated with the equipment supplied
under the contract should be made familiar with the
information contained herein.

It is essential that the personnel engaged on the

installation , commissioning and maintenance of this
equipment are both competent and experienced in these
fields, and that they comply with the relevant statutory
requirements and regulations , including the provisions
of the Health & Safety Act , 1974, and any such modifica-
tions and amendments which may subsequently become a legal
requirement.
 CONTENTS
1.0 TECHNICAL DATA
1.1 For Generator
1.2 For Exciter

2.0 DESCRIPTION
2.1 General
2.2 Bearings
2.3 Cooler
2.4 Illustrations

3.0 INSTALLATION & COMMISSIONING

3.1 Preliminary inspection and storage
3.2 Lifting and handling
3.3 Location
3.5 Oil-lubricated plain bearings - storage and assembly
3.7 Approved lubricants
3.9 Oils
3.10 Alignment
3.12 Flexible couplings
3.13 Dowelling of machines

3.15 Earthing
3.16 Insulation resistance tests
3.17 Removal of moisture
3.18 Methods of drying out windings
3.19 Phasing and connection
3.29 'Elastimold' plug-in connectors ( see also 5.8)
3.31 Neutral terminal box accommodating C.Ts
3.35 Bearing insulation
3.37 CACA coolers ( see also 4.19)
3.39 Putting machine into service - check list ( M/c. with cooler)
3.40 Paralleling

4.0 OPERATION & ROUTINE MAINTENANCE

4.1 General
4.2 Windings
4.3 Adjustment of air-gap
4.9 Pressure- fed plain bearing - operation and maintenance
4.14 Shaft- mounted . rectifier diodes
4.15 A.C. exciter
4.16 Permanent magnet pilot - exciter ( P.M.G.)
4.19 CACA coolers ( see also 3.37)

5.0 OVERHAUL
5.1 Dismantling of generator - general
5.2 Drying out (see 3.16 , 3.17 and 3.18)
5.8 Dismantling of 'Elastimold ' plug-in connectors
5.10 Withdrawal and assembly of a.c. exciter
5.11 Withdrawal and assembly of P.M.G.
5.20 Dismantling of pressure - fed plain bearing
5.21 Removal of rotor
5.22 Re-assembly of generator

Cont'd...
 CONTENTS ( Cont'd)

6.0 SUGGESTED SCHEDULED MAINTENANCE

7.0 SPARES AND RENEWALS

7.1 General
7.2 List of recommended spares
 SECTION 1

1.1 A.C. GENERATOR

S441060 01/02
Serial No.
DG630/1600Q
Frame size
BS5000/99
Specification .. ••
•• 15°C
Air inlet temperature to cooler ..
4194 kVA
Output
0.8 lag
R a ted p ower -factor •• 6600V
Volta g e •• •• 60 Hz
Frequency •• ••
1800 rev/min
Speed •
367A
Full-load stator-current
Class ' F '
Insulation •• ••
.. (CACA) IP55 IC06 61
Enclosure ••

Wi n din g resistances 0 . 056 ohms/phase a t 20°C

St a t o r •• •• • 0.72 ohms at 20°C
Rotor •• ••
.• 8mm
Air-gap ••

Bearing(s) GEC Large Machines

Make •• Glacier 0160 )COO
Type - NOE Glacier 0160 x 80 with taper-
DE - land thrust faces

Automatic voltage regulator GEC Industrial Controls.

Make •• •• C10/120
Type ,. ..

Rectifier diodes Marconi Electronic Devices

Make •• •• •. M201 1200 (R)
Type •• ••

Anti-condensation heaters Hedin

Make •• •• Mat
• 254V
oltage •• •• 1792 watts
Rating .• •.
 TECHNICAL DATA (COnt'd)

A.C. Generator (Cont'd)

Shell
1.1 (Cont'd) Lubricant recommended ) „ Turbo (ISO VG) 46
Make (
Type ( recommended ) •• (8-10) NDE (4-6.5) litres / minute
DE
quantity per bear i ng .. •• 600C
Temperature •• ••
,. 0.7 millibar
switch ••
Differential- pressure
.. 15200 kg
Weight ( approximate) •'
DW4103380
Outline Arrangement drawing

544106003/04
1.2 Exciter ••
Serial No.
• UA339M5
Frame size .
,. 855000/99
Specification •• .. ..
volts 116 amps
Output on rated full 99
Generator load •, 30 volts 43 amps
(100°% volts)
Generator on no load
,. 1800 rev/min
Speed ^ •• •• .. Class 'F'
Insulation ••
IP55 IC06 61
Enclosure •• ••
, ,. Delta
Connection ••
phase at 20°C
0 . 044 ohms /
Rotating armature resistance
9.7 ohms at 20°C
Field winding resistance ••
,. 1.5mm
Air-gap

Excitation data 40 volts 3.4 amps

Rated F /L •• •• •. „ 12 volts 1.2 amps
No load (100% volts).. ••

Ti htenin for use for metric oonltsa head,

ra o bo 18
or ue in
I -Bolt
Diameter I Grade 8.8 Gre e l •

78 136
12 330
16 186
20 I 364
24 I 628
I 1262 1
30
36 I 2170
REG. NO.

27 U$V 1996
 SECTION 2

DESCRIPTION

2.1 General
These 'Unipak' generators are constructed similarly to the
Company's 'Unipak' range of motors.
The stator winding is impregnated by the Vacuum Pressure
Impregnation Process. It is wound into a stator corepack which is
welded together while under hydraulic compression.
The corepack has four feet which are integral with the
endplates to form a stator frame which is bolted down onto the
baseplate via shims which.give correct alignment at the time of
construction and given care will maintain it for the machine's life.
The baseplate being the main structural member also carries the
bearings, endwinding covers, terminal arrangement and top cover. It
also has a welded-on extension outboard of the non-drive end
(N.D.E.) bearing which carries the permanent magnet generator
(P.M.G.) and exciter stators. The baseplate has four feet, being
bolted down by eight M36 bolts.
The four pole brushless rotor has a through shaft which carries
the P.M.G. and exciter rotors outboard of the N.D.E. bearing journal
and a single internal fan at the drive end (D.E.).

2.2 Bearings_
ese are mounted to the baseplate via cartridges. They are
plain white metal bearings with liners split at the horizontal
centre line, contained in two (top and bottom) part housings secured
to the cartridge. They are continuously fed with oil from the
turbine's system via insulated pipework. Both bearings are
insulated from the baseplate at the cartridge to baseplate joint.
It is necessary to insulate both to test the operationally necessary
insulation at the N.D.E. bearing. During normal operation the D.E.
bearing insulation is bridged by a braided copper earthing strap
(see Section 3.35).

WARNING: THE GENERATOR MUST NOT BE RUN UNLESS THE ABOVE EARTHING
STRAP IS IN ITS OPERATING POSITION.

2.3 Cooler
A CACA (air to air) cooler is mounted on top of the top cover.
It cools the air heated by the operation of the generator, which
circulates in a closed circuit. The ambient air is forced through
the open circuit side of the cooler by the two motor driven fans at
the N.D.E. of the cooler.

2.4 Illustrations
The construction of the generator is shown "by the figures with
this section and the outline drawing.
 SECTION 3
.INSTALLATION
& COMMISSIONING
3.1 Pr
zz-t
eliminar ins ection and store e
T
site he chine should be carefull
see if it has been damage y examined when received
are missing . If d during transit or on the
carriers and GEC MachineseLtamaged or missin g if any parts
Should within three day$l ease inform the
goods sent overseas be received of delivery,
whatsoever , any communication that ma damaged , from any cause
Insurance Company or to GEC Machines y be addressed either to
certificate of examination from the nee Ltd.
esthould be bs the
together with ' accompan
by i ed a
Photographic or other Lloyds Surveyor,
Where when or
it is useful
necessary °'"
evidence.
it into service , to to^e
the parts ,
replaced in theirafter wrabeing ins a machine before
9 inspected Putting
Place. pPings and cases a , should be
nd stored in a dry, sheltered
3.2 Lifting and handlin

shackles ) generators are provided with four liftin

the base, positioned
which is near
the the
main bottom
load of the machineg land welded to
bearin
addition ,
be lifting points on the g member. There will, in
for removing the covertop of the machine t
only , , but these are

To prevent damage
to the machine
cover during
lifting, load
spreaders must be
placed between
the four chains
or ropes, as
shown in figure 3.2.

Fig. 3.2.
 3.3 Location
The location of open or drip-proof generators should be kept
dry, well ventilated and free from dust and dirt . Acid fumes or
other corrosive agents should be excluded . Sufficient space should
be left around the machine to allow easy access to all parts, parti-
cularly the exciter and bearings.

Pok
3.5 Oil-lubricated plain bearings - Storage and Assembly
(a) Storage - assembled on the machine
The bearings and housings of the oil-lubricated plain bearing
machines are drained of oil at the end of routine testing to
prevent spillage during transit from the Manufacturer' s Works
to site. The shaft journal and bearing surfaces are treated
with an anti-rust grease (Tiptone 232/PR1) which provides
suitable protection for up to 6 months. Also the shaft is
restrained from all movement at the journal(s) with special
packing (see Fig. 3.5).
If it is required to store the machine for a period longer
than 6 months , then the bearings should be inspected at the
start of this storage period to ensure that complete rust
protectionis present . As an alternative to grease, rust-
preventive oil may be used ( Esso Rust Ban 337).

(b) Storage - separate components

For short term storage ( up to 6 months ) machined surfaces are
protected with anti - rust grease . If the period of storage is
longer, Castrol Rustilo 1501 and Rustilo DW935 are used to form
a hard film protection.

3.5.1 Assembly
Clean the protective coating from all components. Rust-
preventive oil and anti-rust grease only require a final cleaning
with white spirit. The hard film protection may require cleaning
with paraffin . Pedestals shipped as part of a complete machine
should have the packing and steel joint-face shims discarded. (See
Fig. 3.5.)

After aligning the rotor ensure that all covers, screw threads
and joint faces are smeared with a sealing compound ( Hylomar SQ 32M
is recommended ). Covers should be bolted up and the top cap and
seal fitted (see Section 4 for detailed method of assembly). The
seals should be adjusted so that a clearance of 0,05/ 0,075mm is
present between the seal and the underside of the shaft.

A list of recommended grades of oil is given in Section 3.9.

 I Bearing top cap
2 Top half of bearing liner
3 Shaft
4 Packing to provide radial restraint
5 Inverted U shaped packers to give axial restraint
6 Temporary steel shims

Before rotating machine remove packings from bearing(s)

and clean off grease . Discard steel shims (6) before
replacing bearing top cap.

Fig. 3. 5 Shaft packing at bearing(s) for shipment of fully

assembled machine.
/"', 3.7 Approved lubricants
General
The Company does not publish lubricant specifications for the
machines under consideration. The branded lubricants referred to
below have been approved after consideration of their manufac-
turer's specifications and, where desirable, after laboratory and
rig testing. The omission of a lubricant does not necessarily
imply that it has been tested and found unsuitable.
The use of a non-approved lubricant, provided it has been
recommended by a reputable supplier after full consideration of
the application, would not normally be regarded as invalidating
our guarantee.

3.9 Oils
The use of light and medium grade turbine oils to 85489:1974
is recommended for plain bearing machines ,
except in a low ambient
temperature.*
Among the oils which have been approved the following are
widely obtainable : the order of listing is alphabetical
not imply any order of preference. and does

Manufacturer Medium
and Trade Name (BS Viscosity grade VG46)
B.P. Energol THB46
Castrol Perfecto T46
Esso Teresso 46
Gulf Harmony 46
Mobil - DTE Medium
Petrofina Fine Bakola VG46
Shell Turbo T46
Texaco Regal R & 0 46
If the ambient temperature exceeds 30 °C (86°F) or if heavy
shock-loads are likely, always use the medium grade for plain
bearing machines.

* When a machine is to operate in an ambient temperature below

5°C (41°F) the specialised advice of the oil-supplier must be
sought to ensure that an oil with suitable low-temperature
properties is selected.
 3.10 Alai nment
In order to achieve . optimum running quality the alignment of
the machines must be as near perfect as possible . The main types
of misalignment are as follows :- angular, parallel and axial.
,Parallel misalignment is that in which the axes of the two
machines are parallel but are displaced from one another.
Angular displacement is that in which the axes of the two
shafts- are not parallel- but cross or . intersect each other.
Axial displacement is not . quite so. critical but means that the
shaft is not running in its correct=axial position in the bearing
or bearings . ( See Figs. 3 . 10a & 3.lOb.)
Before alignment checks are started it is desirable that the
machine bedplate is set level and. that the machines are set up in
the correct axial positions to give the. axial bearing clearances
as specified on the outline drawing.

FOR DETECTING THIS

TYPE OF ERROR

3.10a
•allel alignment

ZZE^D
FOR DETECTING THIS
TYPE OF ERROR

Fig. (para. ) 3.lOb^C _•_1

Checking angular alignment ^^^
3.12 Flexible cou lin s
T5; acceptable limits of misalignment are usually set by the
prime-mover - manufacturer. The limits given below are intended as
a guide in the absence of such information.

(a) Axial alignment

The relative axial positions of a flexible coupling are
specified by the coupling manufacturer. The two shafts should
be set to give these dimensions as a first step in the
alignment procedure and re-checked as alignment proceeds.
At the same time the axial position(s) of the machine
frame /pedestals should be adjusted to give correct axial
clearances in the bearings, as shown on the outline drawing.

(b) Parallel alignment

With an externally mounted dial- gauge, each half coupling
should be checked separately for concentricity; any out of
truth should be related to shaft position, and recorded.
The radial displacement of one shaft relative to the other
is usually measured by fixing a dial-gauge to one half coupling
to register on a suitable external diameter of the other half
coupling. The two shafts are then rotated together and the
gauge readings noted after each quarter of a turn.
The parallel alignment must be correct to within +0,025mm,
i.e. the total indicated reading must not exceed 0,05mm.

(c) Angular alignment

In principle this is checked by measuring the axial 'gaps' at
the periphery of the half couplings. In practice an arrange-
ment using a dial- gauge as shown in Fig.( para ) 3.10(b) is
often found most convenient.
The coupling halves should be 'match marked' at the 12
o'clock position and the gap-dimension between the coupling
faces measured at the 12, 3, 6 and 9 o'clock positions.
The coupling halves are then turned together (until the
'match marks' are at the 3 o'clock position) and the measure-
ments taken again. This is repeated with the ' match marks' at
6 and 9 o'clock positions. The four readings taken at the top
vertical centre line (12 o'clock position) are averaged,
similarly the four readings at each of the other positions are
averaged.
The difference between the top and bottom readings on the
vertical centre line (i.e. the difference between average rea-
dings at the 12 o'clock position and the 6 o'clock position)
gives a value which is twice the vertical misalignment; and the
difference between the horizontal readings (i.e. between 3 and
9 o'clock positions) gives twice the horizontal misalignment.
The angular alignment must be adjusted until the result
conforms with the Following requirements. For couplings up to
and including 400mm diameter, the difference between opposite
readings must not exceed 0,17mm per metre of coupling diameter.
For couplings greater than 400mm diameter the limit of
acceptability is 0,13mm per metre of coupling diameter.

Cont'd...
 3.12 (Cont'd)

(d) Temperature difference and centre height

Where the shafts of two machines operating at different
temperatures are coupled together through flexible couplings,
it may be necessary to make an allowance for differential
thermal growth of the height of centres.
The allowance to be made for ferrous materials is 0.lmm per
metre of centre height per 10°C temperature difference, the
hotter machine to be set lower when machines are aligned cold.
Final tests for alignment should preferably be carried out
with the set at normal running temperature.
 3.13 Dowelling of machines
Machines despatched as complete units mounted on self-
supporting baseplates will be dowelled before despatch. When
erected on site , line-up should be carried out by movement of the
whole machine so that the dowels and shims need not be disturbed.

3.15 Earthing
The frame should be efficiently earthed by a connection of
substantial cross-section , which should be mechanically and elec-
trically sound. The connection should be inspected regularly and
kept in good order.

POIN
3.16 Insulation-tests before commissioning

General
As soon as the machine has been delivered to site it is
advisable to keep machine windings as dry and clean as possible.
Heaters, if fitted, should be switched on, and kept on con-
tinuously while the machine is inoperative prior to commissioning
or during overhaul periods. Fit temporary heaters if necessary.

Insulation-resistance
The insulation-resistance of a winding gives an indication of
its condition as to moisture and dirt. All new machines and any
machine which may be damp or has been stored or out of service for
a long period should be tested before commissioning. It may be
necessary to dry-out the windings before putting a machine into
service.
Insulation- resistance should be measured between each indivi-
dual phase and earth with the remaining phases earthed. The
insulation - resistance of one phase to earth under these conditions
is approximately twice that of the entire winding (for a 3-phase
winding). Where it is not possib l e eae individual phases,
then the formula given for minimum insulation -resistance must be
applied directly. (See 'Safe ' Minimum Resistances below.) The
high-voltage lead of the d.c. tester is connected between the ter-
minal of the winding ( or phase ) under test and the earth lead to
the frame.
A record should be kept of insulation-resistance readings of
the windings as a trend towards lower readings can be a warning of
impending failure. Tests made immediately after a shutdown, when
the machine is warm, ensure that comparable conditions exist at
each inspection . If abnormally low readings are obtained the
cause should be investigated (see 'Safe' Minimum Resistance
below ); the machine may need to be cleaned and dried out.

3.16.1 Safet precautions

The frame of the machine , along with any sections of the win-
dings which are not being tested, must be adequately earthed. It
is most important that when an insulation -resistance or high-
voltage test is to be made on the rotor the rectifier -diodes are
temporarily short-circuited so that they are not subjected to a
high inverse voltage.
The winding or section under test should be earthed immedia-
tely before and after application of the test potential ; the con-
nections should be left earthed for at least 15 minutes ( 30 min-
utes for large machines ) to allow any residual charge to leak away
before handling conductors or terminals ( a dry , well -insulated
winding can hold an electrical charge for several hours after the
removal of an applied voltage).

(a) Before carrying out a test, see that the surface of the
winding is clean and dry.

(b) Each test voltage is to be applied for one minute before a

reading is taken.

Cont'd...
 3.16.1 (Cont'd)

Safety precaution (Cont'd)

For a new or 'refurbished' machine of any size, initial tests

should be made with a 500 V d.c. tester and may be carried out
without disconnecting the external cables provided that they are
not 'alive', but if unsatisfactory readings are obtained the
winding should be isolated from external cables and the test
repeated.
For machines of over 2000 V, after the initial test with a
500 V tester, the test must be repeated with a tester of voltage
near to the machine phase voltage (for 3-phase machine ); with a
maximum of a 5000 V d.c. tester for machines over 8000 V and up to
16000 V.

to%
Pw% 3.16.2 ' Safe' minimum insulation -resistance
As insulation -resistance varies considerably with different
insulation systems and under different atmospheric conditions it is
difficult to give a specific value for safe minimum-resistance.
However , a practical recommended minimum value, Rm, in megohms,
for the complete winding , at 40°C = kV + 1,
where kV is the rated winding voltage in kilovolts;

or Kt ( kV + 1) = Pon at ambient or machine winding temperature*;

where Kt is a factor dependent on the ambient or winding
temperature at which the test is carried out (see Table)

or Actual resistance*
measured at winding temp. should not be less than kV + 1
Kt

*If the resistance of each individual phase to earth is

measured , the reading should be divided by two (for a 3-phase
winding ) to obtain a value which may be compared with the
recommended minimum.

Values of Kt
I Ambient or I
I winding I 0°C 110°CI 20°CI 30°CI 40°CI 50°C 160°C 170°C I
I temp . i I I I I I I I I
I I
I Kt i 16 i 8 i 4 i 2 i 1 i 1/2 1/4 1/8 1

On clean, new windings, if dry, considerably higher insulation-

resistance values than the minimum given here should be obtained.

Up to 10 MW (10 MVA)
On machines up to 10 MW (or 10 MVA), the insulation-resistance
can be considered satisfactory if it is above the minimum given
above. If the insulation- resistance is below the minimum, then the
polarisation index should also be measured see Polarisation Index
below).

Over 10 MW (10 MVA)

On machines above 10 MW (or 10 MVA) the polarisation index. must
always be measured , even when the insulation -resistance is above
the minimum.

3.16.3 Polarisation Index

The measured insulation-resistance of a winding normally
increases with the time of application of the d.c. test voltage.
The increase is usually rapid for the first 1/2 minute and there-
after the resistance will increase with the duration of the test
voltage up to a steady value. This occurs after about 10 minutes,
and the ratio of the ten-minute insulation-resistance value to the
one-minute insulation -resistance value

R10 rains is called 'polarisation index'.

1 min

Cont'd...
 3.16.3 ( Cont'd)

Polarisation index ( Cont'd)

Polarisation Index tends to be greater when the insulation is

clean and dry.
In order to measure the polarisation index a test equipment
capable of supplying a steady direct current voltage for 10
minutes is necessary (e.g. motorised Megger). For reasons of
accurac the windin s must be earthed for at least 15 minutes (30
minutes for large machines prior to the test in order to allow
any residual charge to leak away.
The effect of temperature on Polarisation Index is small and
can be disregarded.
On a new, clean, dry winding the polarisation index should be
above 1.5.

Up to 10 MW (10 MVA)
Where a stator winding of a machine rated 10 MW ( or 10 MVA) or
below has a one-minute insulation -resistance value below the
recommended minimum but a satisfactory polarisation index, then
the winding is considered acceptable if the ten-minute insulation-
resistance is greater than the recommended minimum. Otherwise a
dry-out is necessary.

Over 10 MW (10 MVA)

On machines above 10 MW (or 10 MVA) both the one-minute insul-
ation-resistance and the polar-isation index must be above their
minimum recommended values, otherwise a dry-out is necessary.

3.17 Removal of moisture from windin insulation - general

a machine has been exposed o unusually damp conditions, or
stored for any length of time in a damp situation, then the wind-
ings may need to be dried out (if insulation-resistance tests and
polarisation index tests show it to be necessary) before normal
voltage is applied.
The winding insulation may be dried out by one of the methods
described later. The time required depends on the initial degree
of dampness and on the size of the machine, and may be from one to
several days.
Whatever method of drying out is used, the rate of temperature
rise should be limited to not more that 5 or 6°C per hour to avoid
damage to the insulation (less than 3°C per hour if the windings
are known to be very damp ). The winding temperature should be
raised to a value of approximately 80°C maximum measured by ther-
mometer attached to the end windings, or to a maximum of 90°C by
embedded temperature -detectors, when fitted, in the windings.
It is essential that the heating process is continuous and
that the temperature reached be maintained throughout the drying-
out period. During this period free discharge and circulation of
air around the windings must be allowed. Any ventilation-covers
encasing the machine must allow slow but continuous interchange of
air with the atmosphere; on totally enclosed machines, covers will
need to be opened.

Cont'd...
 I
N

l i-1 I I 1
I I TEMPERATURE I I I
90

aG vl I -i
I ^ I i l l l
6G i-I Iil Ii i l'i i i
If l
II
1 I
30 i t
40
a
S I I I I i i
10 I i 77 I I I I 1 -^ --- _i
INSULATION RESISTANCE
'n I It/2 z 2' 3 3'12 4

HEATING DRYING OUT TIME-OATS

Fig. 3.17a Plotting of temperature and insulation-resistcncx

taken at regular intervals.

TIME

Fig. 3.17b Graph showing thongs in insulation - resistcncc

 3.17 (Cont'd)
P4k
Removal of moisture from winding insulation - general (Cont'd)

The diagram (Fig.3.17a) shows the trend of insulation-

resistance readings taken during a typical drying-out process. It
will generally be found that, at first, as the temperature of the
windings increases , the insulation- resistance decreases until a
minimum value is reached. This is due, firstly, to a redistri-
bution of the moisture in the windings, and, secondly, to the
inherent drooping temperature -resistance -characteristic of the
insulation. It is for this reason that it is essential to maintain
a constant temperature during the drying-out, for a few degrees
fall in temperature may give a very misleading rise in the value of
the insulation-resistance. Furthermore, if the temperature is
allowed to fall considerably, re-absorption of the moisture may
take place.
After a period, during which the insulation-resistance will
remain practically constant at the minimum value, it will ulti-
mately commence to rise steadily until a maximum value is reached
r and maintained. The progress of drying out may be observed by
taking insulation readings at hourly intervals obtaining both one-
minute and 10-minute readings for the polarisation index. Winding
temperatures , insulation-resistance and polarisation indices
should be recorded at the same regular intervals . ( See Fig.3.17b).
The drying-out process should be continued beyond the time at
which the insulation-resistance has started to increase, and
should be maintained for several hours ( from 6-1/ 2 to 24 hours for
machines from ikV to 13.8kV) after the resistance has reached the
recommended minimum value or the polarisation index is above 1.5.
After drying-out, the winding overhang should be sprayed, or
brushed, with a thin layer of air-drying insulation-varnish. This
should also be done after thorough cleaning during overhaul.

PN
3.18 Methods
Cir of drying hot air
For small machines the simplest method of drying out is to
remove any access covers fitted to the endshield and to place
the complete machine in position where the atmosphere is dry,
free from dust and maintained at a temperature of 80°C. The
method may be further improved by boxing-in the machine and
circulating hot air through it. The air - which must be
thoroughly dried before heating (if possible, by passing it
through a drying chamber containing dry, clean line or cal-
cium chloride) - should be distributed by means of baffles
to ensure equal distribution , and uniform temperature inside
the machine.

(ii) Space heaters

When a machine is known to have only surface moisture, elec-
tric space heaters ( or filament lamps in a small machine) may
be used and should be located both around and inside the
machine, preferably in the air -spaces under the machine end-
windings and distributed so as to allow even distribution of
heat throughout endwindings and core. Care must be taken to
ensure that the winding in the vicinity of the heaters is not
over-heated, and contact between ' heaters and any part of the
windings must be avoided. The machine can be enclosed with
temporary covers to limit radiation-losses.

(iii) Low voltage current

(a) Stators
Where skilled personnel and appropriate means are avail-
able the usual way to dry out a machine is with a low-
voltage direct current. (The stator-windings can be
dried out with or without the rotor being in position.)
All the phases should, if possible, be connected in
series, with copper strip or heavy cable, and the low-
voltage direct current, up to 20% of normal or full load
value, applied to the stator -terminals from any suitable
source of supply e.g. motor-generator set, or rectifier
equipment. The current can be adjusted gradually as the
temperature rises, to increase the temperature by about
5°C per hour, to a maximum temperature of 80°C.

(b) Generator and exciter d.c. field circuits

For drying out d.c. field-windings, all the coils should
be connected in series and the low-voltage direct current
passed through the circuit. The rate of temperature-rise
and the maximum temperature should be limited to the
values given above; the current should never be above
that specified for the machine field-circuit. (As field-
coils are inductive, it is essential when breaking the
circuit (for insulation-resistance readings etc.) to
control the current to a low value by either a resistance
in series with the supply or by reducing the voltage to
as near zero as possible.)

Cont'd...
 3.18 (Cont'd)
OWN Methods of drying out - (iiib) continued

To prevent damage to sliprings at brush-contacts, the

current should be conducted to the stationary rings
through copper-connections.
The rotor should be turned through 90° approximately
every hour or so to obtain an even distribution of heat.
When drying out by low-voltage current, close super-
vision is essential for the heat generated in the wind-
ings is not easily dissipated and one part of the winding
may become exceedingly hot before another has time to
expel the moisture. This can be largely obviated by
taking every precaution to exclude draughts from the
exposed parts of the windings , and if necessary to cover
such parts of the wrappings.
When this method of drying out is used, the external
cables must be disconnected be ore insulation -resistance
readings are taken.

(iv) Short-circuit running (preferred method)

The machine is driven at normal speed throughout the drying-
out process with the stator-winding terminals short-circuited
by bonding together the three main terminals and the neutral
terminals with copper-strip or cable capable of carrying the
full-load current of the machine. Suitable current-trans-
formers should be connected in circuit and approximately the
same current should pass through each phase; if transformers
are not available then other means must be provided to check
the current in each phase. The stator-frame must be effici-
ently earthed.
The exciter-voltage should be adjusted to circulate about
20% of full-load current through the winding during the first
hour; increase the excitation at regular intervals to
increase the winding temperature, by approximately 5°C per
hour. (On high-speed machines sufficient heat may be
generated initially by running the machine at normal speed
without excitation.)
In no circumstances should the full-load current of the
machine be exceeded, and during the process the windings
should be inspected to ensure that they are evenly heated and
that a temperature of 80°C is not exceeded.
During the drying-out period, free discharge and circula-
tion of air around the windings must be allowed. Ventilation-
covers encasing the machine must allow slow but continuous
interchange of air with atmosphere.
3.19 Phasing and connecting to busba^rs
The terminals of most machines built since 1977/1978 are
marked in accordance with &S.4999 Part 3:1977 and are in the
position shown on the outline ' drawing. Terminals of three-phase
generators are marked U, V and W. so that when the machine is
driven with a clockwise rotation looking at ( facing ) the driven
end, the phase voltages attain their maximum values in the
sequence U. V, and W.
-When six terminals are provided , these will be. lettered. U2,
V2 and W2 for the neutral and U1, V1 and Wl for the. line.
terminals.
The phase rotation of the generator should always be checked
before it is connected to the busbars.

4 terminals 3 terminals
6 terminals

Neutral Neutral
Neutral
V2t W2

VI ♦
Line

Fig. 3.19 ^ Stator terminal markings

3.29 Plug-in connectors

General
Mug-in connectors of the 'Elastimold' type are normally
mounted on a steel plate surrounded by a protective enclosure.
Each connector assembly consists essentially of a bushing, a
cable-connector for the outgoing cable and an elbow-housing which
provides the necessary insulation and protects the connection from
moisture and dirt.
Each bushing is provided with a mounting ring designed for
welding or clamping to the mounting plate. The connections
between the machine windings and the inner ends of the bushings
will have been correctly 'made-off' before despatch from the
works. The connector and elbow -housing are assembled on the outer
end of the bushing.

To connect , proceed as follows:-

(a) Remove the protective enclosure from the front of the

terminals.

(b) It is recommended that only one connector is dismantled at one

time. Carefully remove the front insulating cap. This will
expose the hexagon on the front end of the insulating plug.
Unscrew the hexagon and remove the plug.

( c) Remove the insulating elbow-housing by pulling it towards you.

Remove the cable crimp connector from the housing, and also
the cable-adaptor.

(d) Prepare the end of the outgoing cable. Thread it through the
cable-gland in the cable support plate. Slide the cable-
adaptor over the cable-insulation and crimp the connector on
to the cable end.

(e) Insert the cable end complete with connector and adaptor into
the elbow - housing. See that the cable-adaptor forms a good
seal both to the cable and to the elbow-housing.

(f) Place the elbow-housing on the bushing so that the bushing-

screw thread passes through the hole in the connector. Fit
and tighten the insulating plug by means of the hexagon on its
outer end. Replace the pull-off cap. Tighten the support
gland.

(g) Repeat the sequence for the remaining connectors. When all
have been done, replace the protective enclosure.

NOTE: The weight of the incoming cables must not be carried by

the Elastimold Connectors. The cables must be.securely
clamped by glands or other fittings where they enter the
terminal enclosure so that no force is applied to the
connectors.
3.31 Neutral terminal box accommodating C.T's
The complete neutral terminal arrangement is fitted to the
machine during assembly. The connections between the machine
windings and the terminal will have been 'made off' correctly
before despatch from the manufacturer ' s works , and each current-
transformer fitted with a protective short-circuiting link.

To connect, proceed as follows:-

(a) Prepare the incoming cable ends in the appropriate manner for
the type of cable being used. Solder or crimp a thimble to
each cable.

(b) Couple the neutral lead to the appropriate terminal bolt and
secure firmly with the Cleveloc nut provided.

(c) Remove the short-circuiting links from the C.T's and connect
the incoming C.T. leads to the appropriate C.T. terminals.
For the protection-C.T. connections see machine outline
drawing and for the excitation-C.T. connections see A.V.R.
connection diagram.

CAUTION: Do not remove the short-circuiting link from any

C.T. unless the burden is ready to be connected.

(d) Re-assemble the cable -gland assemblies to grip the cables and
complete the sealing of the cable entry.

(e) Replace the front cover-plate ensuring that the gaskets are
undamaged and correctly assembled.
 3.35 bearing insulation
ON%
Under certain conditions , a "difference of potential can be set
up along the rotating shaft, causing a current to flow through the
bearings , bearing cartridges and baseplate , resulting in pitting
of the bearings or shaft. To break this current, the bearing
cartridges are fully insulated from the base as shown in Fig.3.35.

At the drive end, an earthing link is fitted to prevent a

dangerous voltage to earth occuring on the rotating parts. To
check the integrity of this insulation proceed as follows:-

( 1) Remove the earthing link at the drive and.

(2) The generator should not be connected to the driving engine or

turbine at this stage , but if it isy. it should be uncoupled
unless the coupling is insulated.

Fig.3.35 Bearing insulation arrangement at the drive end showing

the earthing strap
Cont'd...
3.35 (Cont'd)

(3) Using a 500 V megger measure the resistance between the

bearing pedestal and the baseplate at each end. On a new
machine it should be greater than 50,000 ohm, but on a machine
which is being recommissioned after service , a figure as low
as 1000 ohm is acceptable.

(4) If the resistance value is below 1000 ohm the cause should be
investigated . It will usually be due to damaged insulation or
an accumulation of conducting material around the cartridge
feet.

(5) Replace the earthing link. The generator should not be run
without this link in position.

(6) Any metal connections made to insulated bearings such as oil

pipes, instruments etc. must also be insulated so that they do
no netralise the effect of the bearing insulation.
 3.37 CACA coolers (See also 4.19)
Isolate the machine before doing any work on the cooler.

The following checks should be made before the cooler is first

put into service or returned to service after maintenance work:

(a) The fans should rotate freely , and should have adequate
clearance around them.

(b) The complete cooler, and the tubes in particular , must be free
of foreign bodies.

(c) Check the supply to the fan motors and check that they run and
blow in the correct direction.

(d) Anti-reverse flow dampers are fitted . Check that these flaps
move freely and that they function to prevent reverse flow
through the dead fan with each fan running alone.

(e) Pressure switches are fitted to the cooler . They will have
been pre-set to operate when a fan unit fails . The switches
should be checked for correct operation.

r
 3.39 Puttin machine into service - check list
en a new machine ( or one that has been dismantled and re-
assembled ) has been installed and aligned the following checks
should be made before putting the machine into service:

a) Make sure that all the appropriate fixing details (e.g.

foundation and holding-down bolts, coupling bolts etc.) are
tight and secure.

b) Check that all the external supplies are operating correctly,

(fan-motor supply in the case of CACA cooler, oil supply pump
etc.)

c) The connections should be compared with the connection diagram

supplied with each machine. All electrical joints must be
firmly tightened up.
All clearances between live parts and earth should be checked.

d) Check that all connections to the excitation equipment agree

with the drawings.
ON,
e) Pressure-fed bearings are fitted and the specified rate of oil
flow for each bearing must be obtained as accurately as
possible. See Technical Data (Section 1).

f) Ensure that all moving parts and air inlet/outlet areas are
free from obstructions.

g) Make sure that all electrically alive parts are free from
external interference and that all covers are fitted.

Having completed these checks the following items should be

observed an initial start-up:

h) Check the direction of rotation of generator/prime mover

system and make sure that the phase sequence agrees with the
phase sequence of the system to which it is to be connected.

r'% j) The generator should be run for some time without load in
order to get the surface of the bearings in good condition.

k) Bearing vibration should be checked.

The bearing temperature should also be measured and, when
stabilised , a record made of the running temperature.
3.40 Parallelin
closing the generator main circuit-breaker that con-
nects the stator windings to the busbars, the machine must be run-
ning perfectly in synchronism with the system, as indicated by the
synchronising equipment , and the voltage of the machine must be
the same as the voltage of the system busbars, as indicated by the
paralleling voltmeter . If both these conditions are obtained, no
current will flow from the incoming machine when it is connected
to the busbars. After the generator has been paralleled onto the
busbars, ' the governor setting of the prime -mover should be adjus-
ted, by hand or automatically , to apply load to the generator.
The excitation should then be increased by hand or automatically
by a voltage - regulator, so that the power -factor of the generator
may correspond with that of other machines on the system.
Brushless generators must never be started from another supply as
synchronous motors, since this will subject the diodes to a high
inverse voltage and may cause them to fail.
Except in special cases, specifically mentioned by GEC , paral-
leling must always be carried out automatically or by means of a
check-synchroniser , synchroscope or synchronising lamps ; careless
paralleling must be rigorously avoided.
 SECTION 4

OPERATION & ROUTINE MAINTENANCE

4.1 General
Moisture, oil, dirt, grease, and carbon or metallic dust are
the principal causes of electrical breakdown: machines should be
kept clean and dry both inside and outside.
All machines require to be dismantled, cleaned and examined
from time to time, but it is impossible to give any ruling on the
frequency of successive cleaning since this will depend on the
conditions under which the machines operate. Machines should not
be dismantled more frequently than necessary.
Cleaning should be done with clean, dry , low-pressure compres-
sed air, bellows , or a brush , and adjacent apparatus should be
protected by covers during the operation . When cleaning, ensure
that air-passages in the stator and rotor are cleaned of any
accumulated dirt.
Where possible, the tendency should be to blow dirt from
inside the machine to outside, to ensure that the air stream does
not carry dirt from one surface to another perhaps less
accessible.
Terminals and all screw connections should be kept clean and
tight. If they become dirty or corroded, they should be discon-
nected and all contact surfaces made clean and smooth. Bad
contacts lead to sparking , and ultimately to breakdown.
When machine is supplied with insulated bearings, the
insulation should be checked; see Section 3.35.

4.2 Windings
Greasy deposits can be removed by rubbing with a lint-free
cloth dampened with white spirit or trichloroethane. (These
solvents should only be used in well-ventilated places and care
should be taken with regard to naked flames.) On no account
should solvents be allowed to soak into the windings as this
causes porosity of the insulation allowing penetration of semi-
conducting dirt detrimental to insulation-resistance.
Hardened dirt may be removed by brushing, with a fairly stiff
brush. Do not use wire brushes or scrape with a knife on windings
or leads. The stator winding supports and lashings should be
inspected for rigidity. After cleaning, the insulation-resistance
should be tested with a Megger or similar testing set to see
whether the reading is satisfactory. (For minimum Insulation-
Resistance , see Sections 3.16, 3.17 and 3.18).

4.3 Adjustment of air-gap

Although the air-gap between the stator and the revolving face
of the rotor is usually comparatively large, it is important for
satisfactory operation that the gap be uniform the whole way round
the bore of the stator. Measurements should therefore be made
from time to time to see if the gap has become unequal.

Cont'd...
 4.3 (Cont'd)

The following method of checking the air gap is used during

manufacture and is recommended for use on Site. In principle the
air-gap is considered uniform if the rotor pole surface is
concentric with the outside diameter of the stator laminations.
An accurately measuring depth gauge is fed down a stator core duct
to beer on the approximate centreline of a pole shoe taking care
to avoid any damper winding slots. Choose a pole which is
reasonably free of excrescences of varnish and turn the rotor so
that this pole is in the 12 o'clock position. Take measurements
on this pole at both ends of the stator, and repeat the readings
in the 3 o'clock and 9 o'clock positions turning the rotor so that
measurements are made against the same pole in all cases.
The difference between the maximum and minimum readings taken
above is a measure of the variation in the air - gap and should not
exceed 10% of the air gap diemsnion given in Section 1.
Long gapping feeler gauges can alternatively be used to take
actual gap measurements . The feelers should penetrate the gap at
least 100mm at both ends of the stator but access to the gap may
/"N be restricted at the drive end by the fan.
The vertical air-gap may be adjusted by means of altering the
stator frame shims. Jacking screws are fitted to each foot to
facilitate adjustment
 4.9 Pressure-fed plain bearing - Operation and Maintenance
For pressure -fed bearings , the frequency of oil changes
needed will depend on the oil-filtration equipment in use.
With low-pressure lubricated bearings, supplied with oil from
a separate source, care should be taken to ensure that the correct
oil-quantity is supplied to each bearing and that maximum
temperature of the inlet-oil is not exceeded. (See Technical
Data Section 1 and the Outline drawing.)
Failure to observe these precautions may result in damage to
the bearings and/or cause flooding and leakage of oil from the
bearings.

I",
 4.14 Shaft-mounted rectifier diodes
The diodes mounted on the rotor are selected to suit the
generator excitation requirements and should give trouble-free
service for an indefinite period. A three-phase bridge connection
is used as shown in Fig. 4.14; the protective resistor, when
fitted, is to prevent the build up of high-transient voltages in
the main generator field winding during fault conditions, which
would otherwise be harmful to the diodes.

If a diode failure should ever occur the effect on the

generator will depend on the nature of the failure:-

Diode fault I Effect on generator Remed y

i
I One open-circuit I Small increase in I Replacement requiredI
I diode I excitation current of I at first convenient I
1 I approximately 5% I opportunity but I
I immediate shutdown I
1 I not essential I

1 Several open- I Significant increase I Replacement requiredI

I circuit diodes I in excitation current I as soon as possible,I
I but normal output I i.e. within minutes I
1 probably attainable I of fault occurring I
I but immediate shut- I
1 I down not essential I

I One or more I Impossible to achieve I Shutdown immediately)

I short-circuit I more than small frac - I and make appropriateI
1 diodes I tion of max. generator ) replacements .1
output; exciter will I I
I be subject to consid-
erable overload I 1

Replacement diodes must always be of the same polarity as the

originals , as indicated by the type reference marked on the diode
(e.g. M201-120OR for negative heat-sinks and M201-1200 for
positive heat-sinks ). Diodes can be checked for complete open-
circuit or complete short-circuit in situ, once one connection to
the diode has been disconnected , with an Avometer . Such a meter
will indicate a comparatively low 'forward' resistance ( e.g. less
than 1000 ohms) and a high ' reverse ' resistance ( e.g. greater than
100 kohms) for a healthy diode, but a perfectly healthy set of
diodes may not give identical resistances in any one direction.
Any diode whose condition is suspect should be returned to GEC
Large Machines Ltd. for comprehensive testing.

104, Cont'd...
 Varistor Diodes

Exciter Exciter
armature - ] field

Fig. 4.14 Typical rotor connections

Connections
to diode

Varistor

Connections to
rectifier hub

Rectifier
diode

Fig. 4.15 Typical exciter arrangement

 4.14 (Cont'd)

When fitting replacement diode it is important to use a

suitable jointing compound to ensure good heat -transfer and a good
electrical joint. We recommend and use Midland Silicones 'Heat
Sink Compountd DP2623'. Remove the old diode from the heat sink
and clean the heat sink surface with a cloth dampened with white
spirit. Immediately apply an even layer of heat sink compound.
Rub the contact face of the diode on a cloth until bright, then
screw into place on the heat sink. The diode should be tightened
to a torque of 27 Nm. Ensure that there is an even contact area
between the diode and heat sink.

NOTE: New diodes may be supplied with a locking washer for use
with a backnut. These items should be discarded in the
above application.

4.15 A.C. exciter

A typical exciter is shown in Fig.4.15 . The air-gap should be
sensibly constant all round the armature . From time to time its
value should be checked with feeler gauges to ensure that the
variation in air-gap does not exceed 10% of the average measured
gap. Any adjustments to the air - gap may be made by altering the
shims under the stator core feet.

/R
 4.16 Permanent magnet pilot-exciter ( P.M.G.)
The P.M.G. is fitted inboard of the exciter within the exciter
enclosure . The air-gap should be sensibly constant under each
pole. From time to time its value should be checked with non-
magnetic feeler gauges to ensure that the variation in air-gap
does not exceed 10% of the average measured gap. Any adjustments
to the air - gap may be made by altering the shims under the stator
core feet.

T
 4.19 CACA Coolers (See also 3.37)
To maintain the efficiency of the cooler, the cooling-air
passages should be examined periodically and cleaned if necessary.
The frequency of cleaning will depend on the environment but
deposits of dirt on the air inlet mesh would indicate that
cleaning is necessary. The tubes should be cleaned with a
suitable brush, obtainable from the cooler-manufacturer.
Detergent and water may be a useful aid in removing stubborn
deposits.
Fan driving motors may require periodic lubrication of the
bearings , and damper -bushes should likewise receive periodic
lubrication with a light oil.

r
 SECTION 5

OVERHAUL

5.1 Dismantling of generator - General

The following instructions are for the complete dismantling of
the machine. Where only partial dismantling is required the
appropriate section should be used with discretion.

Disconnection ( electrical and mechanical)

Iso late from all electrical supplies. It is important that
all necessary safety precautions should be taken.

Procedure
Lock-out the main circuit-breaker. Remove all fuses from all
auxiliary supplies . Disconnect the prime-mover starting circuits.
Disconnect all main and auxiliary cables, carefully labelling each
one. Disconnect bearing oil pipes as necessary.

Remove any temperature measuring devices from the bearings.

Remove cooler and enclosing covers.

Remove all stator dowels and holding-down bolts

Remove bearing pedestal caps and bearing top half. ( See also
the relevant Sections 5.14 to 5.19 inc.)
Protect the bearing shells and journals from damage and
contamination of the sump by foreign matter.

If not already marked, 'match mark' the coupling and remove

coupling bolts.

It is not normally necessary to remove the covers from the

machine to give access to the bearings for examination.

5.2 Drying out

Refer to Sections 3.16, 3.17 and 3.18.
T

/'"
5.8 Dismantling of plug - in connectors

( a) Remove the protective enclosure.

(b) For each connector assembly , remove the front insulating cap.
This will expose the hexagon on the front of the insulating
plug. Unscrew the hexagon and remove the plug.

( c) Slacken the cable -support gland or clamp.

(d) Pull the elbow-housing gently towards you until the connector
is free of the threaded connection on the end of the bushing.
Pull the cable and connector free of the elbow -housing and
through the cable-support gland or clamp. ( If cable-support
glands are used it will also be necessary to remove the cable-
adaptor from the cable before passing the cable through the
gland.)

(e) Reassemble the elbow-housing, insulating plug and insulating

cap so that they are not lost.
5.10 Withdrawal and assembly of a.c. exciter
The exciter connections are shown diagrammatically on the main
generator connection diagram supplied with the machine. A typical
exciter is shown in Fig. 4.15 (Section/para.4.15).
The exciter- armature complete with the rectifier-hub can be
removed and replaced, using the withdrawal/ replacement gear.

Withdrawal of exciter armature (refer to Fig. 5.10)

( a ) Disconnect shaft-cables from rectifier hub.

(b) Remove screws , shakeproof washers and release the tacho-

bracket, part 6, from the shaft end.

(c) Screw in the four withdrawal studs, part 2.

(d) Position the withdrawal fixture, part 1, on to the end of the

shaft as shown.

(e) With nuts, part 3, threaded on part 2, tighten evenly to

withdraw exciter-armature until fit is disengaged.

(f) Fully withdraw armature and withdrawal fixture. Remove nuts,

studs and withdrawal fixture.

Assembl of exciter- armature (refer to Fig. 5.10)

g Thread exciter -armature on to shaft until it begins to engage
on fit diameter.

(h) Fit studs, part 4, into tapped holes in end of shaft. Fit
tacho-bracket, part 6, spacer tubes, part . 7 and washers and
nuts, part 5. Tighten nuts evenly to push exciter armature up
to shoulder on shaft.

(j) Remove nuts , washers, spacer tubes ans studs, and replace with
shakeproof washers and screws , previously removed in step (b),
to secure tacho-bracket and armature in position.

(k) Reconnect the shaft cables to the rectifier hub.

5.11 Withdrawal and assembly of P.M.G.

The P.M.G. is foot mounted within the exciter housing.

Withdrawal
a Remove the exciter covers.

(b) Disconnect the stator connections on the P.M.G . and exciter

and remove the holding down bolts.

(c) Carefully remove the exciter stator.

( d) Remove the exciter armature (see 5.10).

( e) Remove the P.M.G. stator.

(f) To remove the P.M.G. rotor.

Reassembl y
g Refit the P.M.G. rotor.

(h) Refit the P.M.G. stator and check the air-gap ( see 3.14 and
4.16).

(i) Refit exciter armature and reconnect exciter shaft leads (see
5.10).

( j) Refit exciter stator and check the air -gap (see 3.14).

(k) Reconnect P.M.G. and exciter connections and check all holding
down bolts are tightened.

( 1) Refit the exciter covers.

 5.20 Dismantlin of ressure -fed plain bearings
( a ) emove all instrumentation.

(b) Remove the bolts and dowels securing the bearing cap.

(c) Remove the bearing cap but take great care at this stage
because the top half bearing shell may stick in the cap and be
lifted with it. If it is lifted it may fall unexpectedly
causing either injury or damage.

Prevent foreign bodies or dirt from falling into the bearing

housing.

( d) Remove the top half bearing shell and examine.

(e) Before removing the bottom half shell the weight of the shaft
on the bearing must be relieved by means of a lifting sling or
hydraulic jack. Take care not to damage any machined surfaces
with the lifting equipment.

(f) The bottom half bearing shell is now free and can be slid or
tapped, using a brass or hardwood 'dolly', round the shaft
until it is on top of the journal and clear of its seating.
The bottom half shell can now be removed and examined.

}^`

r
5.21 Removal of rotor

General
This task is performed by lifting the combined stator and rotor
away from the baseplate and unthreading the rotor towards the driven
(D.E.) of the stator.
CAUTION: The threading and unthreading of the rotor is a delicate
operation require skill, care and the proper equipment. The
endwindings projecting beyond each end of the stator core
are particularly vulnerable and the rotor must not be
dropped or lowered onto them or nudged into them. A two-
hook crane should be used for the unthreading operation.

Preparation procedure

WARNING
First ensure electrical and mechanical safety. Lock-out and
label the main circuit breaker. Remove fuses from all auxiliary
supplies . Disconnect the starting circuits of the driving engine or
turbine.

Then disconnect items which will obstruct necessary movements.

1) Disconnect all main and auxiliary cables, carefully labelling

each one and tying back away from dirt and damage risk where
required.

2) If bearings have external oil supply (check Technical Data,

Section 1), disconnect the oil supply pipes.

3) Disconnect temperature measuring devices from the bearings.

4) If a top mounted neutral switch box is fitted (see Technical

Data, Section 1 ), disconnect it and its cable connection through
the overall cover.

5) Remove cooler (if fitted) and enclosing covers.

6) Remove the holding -down bolts and dowels which secure the
exciter and permanent magnet generator ( P.M.G.) frames.

7) Remove the above frames by moving each along the baseplate

towards N . D.E. and lifting away after the shaft end has been
cleared.

CAUTION: The air-gaps on P.M.G. and exciter are very small (see
Technical Data, Section 1), so take great care on Item 7
above.

8) Turn the main generator rotor so that it will rest via packing
on two of its poles when the drive coupling is disconnected and
bearing cartridge holding down bolts are undone.

9) Insert packing between the rotor and stator bore. Use clean,
strong , pressboard or similar material . For amount needed refer
to Technical Data, Section 1 for air gap.

10) Remove all the stator and bearing cartridge dowels and holding
down bolts. Do not disturb the corepack shims, which should be
left bolted down onto the baseplate.
 5.21 (Cont'd)

Removal of rotor
This requires:-

1) A crane sufficient to lift the combined weight of rotor and

stator.
2) Sufficient headroom to lift bottom of stator clear of
baseplate.

3) A space to place rotor and stator combined with room and

crane provision to unthread the rotor towards N.D.E.

The relevant weights and withdrawal distances are shown on

Outline Drawing and Technical Data, Section 1.

Procedure
1) Li the combined stator and rotor by shackles applied to the
,lifting lugs on the stator frame.

2) Lift clear of baseplate.

3) Run out towards N.D.E.

4) Set the combined stator and rotor down in a clear area (see
requirement 3 above).
5) Pull the exciter rotor and P.M.G. rotor off the shaft towards
N.D.E.
For this, use a pulling plate over shaft N.D.E . and studs
screwed into the holes in the hub of each rotor (see Sections
5.10 and 5.11).

6) Strip down the N.D.E . air seal.

7) Place support blocks under the N.D.E. bearing - cartridge feet.

0^ 8) Refer to Section 5.20 and dismantle and N.D.E. bearing.

Remove the lower-half bearing housing from cartridge and then
remove cartridge over N.D.E. of shaft.

9) Place slings round shaft at each end and take the weight of
the rotor on the crane.

10) Ease the rotor through stator bore towards D.E., until the
N.D.E. sling is as near as possible to stator without risk of
damaging the endwinding. The point of balance of rotor should
have emerged.

11) Place a strap around the poles at the rotor ' s point of balance
and use it to support the weight of the rotor.

12) Remove the sling from N.D.E. of shaft and complete the
unthreading of rotor and shaft from stator.
Cont'd...
T
 5.22 (Cont'd)

10) Assemble the bottom half bearing housings and bottom half
liners.

11) Remove the packing from between rotor and stator bore and
gently lower the rotor onto the bottom half bearing liners and
complete reassembly of the bearing.

12) Test the bearing insulation resistance before going further

( see Section 3.35).

13) Complete reassembly of the generator but leave driving coupling

parted unless it is insulated.

14) Finally test the bearing insulation.

15) Reconnect the coupling.

End of procedure.

r'`
5.22 Re-assembl of the generator
The starting point for this task will be:-

1. Baseplate
sor corepack shims must be bolted in their positions,
The tat
clean and undamaged . Preferably , they will be so having never been
disturbed . If they have been disturbed , it will be necessary to
check and probably reset the axial alignment and concentricity of
the stator.

The bottom half of the N.D.E. bearing must be put in its place
in the baseplate.

2. Stator
Standing in a clear area under crane run with room to manoeuvre
rotor at the D.E.

3. Rotor
Resting on wooden supports under crane run with bearings and
exciter and P.M.G. rotors removed (see 1. above for correct
position of of N.D. E. bearing bottom half).

4. Seals
Check their condition before starting to re-assemble. Have
replacements ready for any which have deteriorated.

Procedure
This procedure is in general the reverse of that for removal of
rotor etc., but note the points emphasised below.

1) Place the packing in the stator bore ready for the rotor to
rest upon.

2) Ensure that rotor when rethreaded will rest via packing on two
of its poles.

3) Rethread rotor into stator, N.D.E. first into stator D.E. and
rest it via packing in stator bore.

4) Reassemble the N.D.E. air seal.

5) Remount the P.M.G. and exciter rotors . ( See Sections 5.10 and
5.11).

6) Lift the combined stator and rotor and move it over its
mountings in the baseplate.

7) Lower the combined stator and rotor. Use the jacking screws to
steady the stator and engage the dowels in the baseplate while
the weight is still on the crane.

8) Take the N.D.E. bearing cartridge over the exciter and P.M.G.
rotors and remount it.

9) Apply slings to the rotor and lift it with care as far as the
air-gap permits.
Cont'd...
 5.21 (Cont'd)

13) Replace the sling at N.D.E . of shaft and set rotor down
carefully onto wooden supports in a clear area.

CAUTION: Take care not to damage the field coils, bearing journals
or fan.

End of procedure.

rk
 SECTION 6

SUGGESTED SCHEDULED MAINTENANCE

6.0 General
It is strongly recommended that a regular system of scheduled
maintenance be adopted and a record card be prepared , giving
details and dates of insulation - resistance readings, and any
eventful faults, repairs, replacements and overhauls.
The following paragraphs list the various items to which
attention should be given and suggest the frequency it is
required . Operating experience under particular site-conditions
may show that less or more frequent attention is required.
Heaters , if fitted , should be switched on and kept on
continuously while the machine is inoperative prior to
commissioning and during normal shut down periods . Fit temporary
heaters if necessary.

6.1 Daily
a Bearings
( i) Inspect for any leakage of oil along shaft.

( ii) Check bearing temperatures.

(iii) With forced feed or circulating oil
Check oil flow from the drain and that an adequate
supply of oil is being maintained , by visual
observation of oil-flow-relays or pressure gauges.

(b) Oil system

Check oil level in the sump-tank and carry out routine
inspection of all working parts.
Inspect pipes for leakage

6.2 Weekl
Check all nuts and bolts , including holding-down bolts,
frequently during the first few months of running (later, check
these every three months).

6.3 Monthl
Carry out visual inspection of oil and air-systems, clean
filter/strainers if necessary.

6.4 Three-monthl y
a Carry out visual inspection of windings and cooler (if
fitted).

( b) Test bearing insulation.

(c) Test stator-insulation -resistance , and at any time immediately
before putting machine into service (See Sections 3.16 & 3.17)

(d) Check all connections , and all nuts / bolts including holding-
down bolts.

( e) Check that there is not excessive play in the coupling.

(f) Take oil -samples for analysis (if required).

6.5 Six-monthly
Measure and record insulation-resistance of all windings.

6.6 Annually

Ventilation
a Clean all ventilating ducts and passages.

( b) Clean cooler -tubes.

Winding s
c Inspect and clean windings and test insulation resistance.
(See Sections 3.17 and 3.18).

(d) Check slot- wedges and winding supports.

(e) Check connections from windings to terminal box.

Sleeve bearings
Remove bearing bushes for visual inspection and cleaning.
( Check bearing and pipework -insulation - resistance).

(g) Replace bottom half bearing bush and check clearances for
alignment . ( Clearance should be equal on both sides and at
each end of the bush.)

(h) Replace top half bearing bush and check top clearance between
shaft and bush.
 SECTION 7

SPARES AND RENEWALS

7.0 In order to save delay and inconvenience, the following

information should be supplied when ordering spare parts:-

(a) Full particulars of the machine including Serial No., as given

on nameplate.

(b) Describe fully the part or parts required.

(c) When ordering a bearing, state for which end of the machine it
is required. Ball or roller bearings can be ordered either from
GEC Large Machines Limited or direct from the bearing
manufacturers. In the latter event, state that they are for an
electrical machine to ensure that they have the correct
diametric clearances between the balls or rollers, and the race.

'a'. (d) Rectifier-diodes - quote the type.

7.1 It is important to arrange the storage of spares in a manner

that ensures their readiness for use at the shortest possible
notice. All spares and particularly insulated parts should be
stored in a clean, dry environment.
If the spares must be stored in a damp or contaminated
atmosphere special precautions are necessary for their protection.
Therefore, when ordering spares it is important to advise full
particulars of storage conditions.
Storage of parts in conditions of rapidly changing temperature
should be avoided, since such conditions will cause condensation and
consequent deterioration of any insulated parts. Where ambient
conditions of this nature are likely, the spares should be stored in
a room the temperature of which can be controlled and maintained
reasonably constant.

7.2 List of recommended spares

The following is a list of minimum quantities which should be
r held on site. These quantities should be increased if there are
identical machines on the site.

One set of rectifer-diodes.

One set of bearings or bearing liners.

 TECHNICAL MANUAL

for

2 GENERATOR CONTROL SUITE

Supplied to

GEC LARGE MACHINES

for

RUSTON GAS TURBINES

for

HAMILTON BROS -DUNCAN FIELD

Customer ' s Order No . $44106005

Customer Specification S96277

GEC Industrial Controls Limited

Technical Manuals - Rugby
Technical Manual No. 032785/84
 SAF ETY INSTRUCTIONS
#"%?tTLE
Health & Safety Statement for Customer's Manuals. No J/9020/02
Sht. 1 Cont.on 2

FOREWORD
UK HEALTH AND SAFETY AT coax ACT (HSAWA) 1974.

Compliance with Instructions in this Manual

The purchaser should comply with the instructions and information in this
manual and all personnel to be associated with the apparatus under this
contract should be made familiar with the information contained herein. The
user should note that the requirements
of this Foreword apply only to the
apparatus. supplied for installation and use in the United Kingdom•(UK) and
which are therefore subject to the UK Health and Safety at Work Act, 1974.

Guidance Notes for Users on the Safety of Personnel using Electrical Apparatus

The-above Act stipulates that electrical apparatus shall be designed, tested

and installed to be safe and without risk to health when properly used and
that information is provided on the conditions necessary for safety and on any
hazards which could. arise during normal use and how these are to be avoided...
See Section 6 of HSAWA.

The above Act stipulates that, the User, on his part, shall ensure that his
employees are: informed, trained and supervised and use proper working procedures
to ensure their safety . He is advised to comply with the information
provided
in order to maintain the plant in a safe condition.... See Section 2 of HSAWA.

Compliance with these two basic requirements ensures that under normal healthy
plant operating conditions 'the apparatus will be safe for use by electrically
unskilled operators.

With certain categories of apparatus as identified later in this Section,

safety hazards may arise , when it is necessary to gain access
by opening
enclosures, removing covers etc.., in order to carry out maintenance work,
testing , setting-up etc. This is, especially the case when the apparatus
cannot be completely isolated before working on it, as for example, where
circuits must be energised for the purpose of carrying out electrical tests.
As it is often impracticable or impossible to achieve hazard free conditions
when working with energised circuits, the main burden of responsibility for
the safe conduct of those carrying out the work, rests on. those under whose
authority they act.... See Section Z of HSAWA.

Installation, Operation and Maintenance

The purchaser is advised to ensure that the apparatus supplied by the Company
to the purchaser's order is correctly installed, is a suitable location, by
technically qualified and competent persons experienced
in the class of work
involved.

The rules for ensuring the safety of personnel can be-summarised under the
following headings:
SAFETY INS T RUCTIONS.'.
No J/9020/02
Health & Safety Statement for Customer ' s Manuals.
Sht. ,3- Canton 4

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 CONTENTS

SECTION 1 GENERATOR CONTROL PANEL DESCRIPTION

SECTION 2 COMPONENT LIST

SECTION 3 DRAWING LIST

SECTION 4 TECHNICAL MANUALS FOR:-

AVR C10/120 B3 AND B4 WITH HAND CONTROL HC12

FV200A3 OV/UV PROTECTION UNIT

FV223 B1 DIODE FAILURE DETECTOR

FYC42 CHECK SYNCHRONISING UNIT

ROCHESTER & INSTRUMENT SYSTEMS SERIES TM2480

TEMPERATURE MONITOR

COMPONENT SUPPLIERS LEAFLETS

 DUNCAN FIELD

GENERATOR CONTROL PANEL

S/0. 03 278501

INTRODUCTION

The control panel for the two generators comprises a free standing
sheet steel cubicle with a fixed synchronising panel between hinged
lockable wardrobe doors and welded rear panels.

The cubicle accommodates components of various electrical circuits

which are described below.

The reader of this description should make reference to the circuit

diagram, the relevant sheet numbers of which are noted in each part.

1. EXCITATION

General

Equipment for supplying the exciter field and thus determining the
generator output voltage is accommodated within the cubicle.
Refer to drwg. RE1/C15202 - sheet 1.

The generator rotor is excited with D.C. which is obtained from the
a.c. output of an induction generator exciter rectified by diodes
carried on the rotor itself. Control of the generator voltage is
obtained by controlling the exciter field.

The exciter field is supplied from a permanent magnet generator

pilot exciter (PMG) via a static automatic voltage regulator
(A.V.R.) type C10/120 a detailed description of which will be found
in the appropriate leaflet.

A field discharge path is provided via a zener diode in the HC12

hand control unit and the exciter field ballast resistor which is
inserted in the field circuit by the de-energising of the
excitation contactor (Exc).

1.1 Excitation Control

The supply from the pilot exciter to the exciter field passes
through contacts of the excitation contactor being closed to obtain
excitation . The excitation contactor is closed automatically
provided the excitation sel. switch (auto/off/trip) is in the auto
position and the local/remote switch in the 'local' position.
This condition also applies if the local/remote switch is in the
'remote' position and the remote latched close/trip pushbuttons are
in closed position. ' (Sheet 3 of drwg.). Certain conditions
prevent closure or trip the excitation contactor namely :

Continued....
 (a) The turbine has not reached 95% of full speed.

(b) Generator protection has operated - master trip relay

energised (hand reset).

(c) Diodes in rotor circuit have failed (short circuit) -

diode failure pilot relay energised.

1.2 Automatic excitation control ( contactor H.A.C. energised)

The required voltage setting can be obtained by adjusting a

motorised auto volts trimmer (MAVT). There is a
raise /neutral/lower switch in the panel and a duplicate one in the
remote position switched into circuit by the local/remote switch
for controlling the potentiometer motor. The potentiometer sets
the reference for the automatic voltage regulator (AVR), generator
voltage feedback is from the sensing transformer located in the
switchgear. The pilot exciter (PMG) output is rectified and
regulated by the AVR and fed through contacts of Hand/auto
contactor in auto position to the exciter field.

1.3 Manual Excitation Control ( HAC de-energised i.e. hand/auto)

(switch in ' hand ' position.

The pilot exciter ( PMG) output is adjusted to the chosen value by a

motor driven variable transformer ( sheet 3 ) and rectified in the
hand control unit (HC12) before passing through HAC contacts to the
exciter field.

Spring return, manual Raise/neutral/lower switches are situated in

local and remote positions for controlling the variable transformer
motor.

2. PROTECTION

2.1 Diode failure detection. (Sheet 1)

Failure of the main excitation diodes in the generator is detected

by monitoring the ripple present in the exciter field current.
(See sht. 1 & 3). The exciter current is passed through a shunt
resistor and the voltage drop across the resistor is monitored by a
detector unit (FV223), both resistor and detector being mounted
inside the cubicle.

If an open circuit diode is detected a relay DFPR2 is energised

(sht.3) which gives a signal to the turbine control module, but if
a short circuit diode is detected relay DFPR1 is energised which
trips the excitation contactor and provides a signal to the master
trip relay (in switchgear) which trips the generator circuit
breaker.

Continued...
A

For details of detector unit FV223 refer to leaflet.

Note an indicator lamp (ROTATING DIODE FAILURE) lights when either

Diode failure pilot relay DFPR1 or DFPR2 is energised. (Short and
Open circuit respectively).

2.2 FV200 Over/Under Voltage Unit (Sheet 1).

This unit protects the generator and its load against a fault in
the excitation circuit.

A special feature of the relay is the use of a current compounding

circuit to give effective discriminating protection when a number
of sets are operated in parallel. This ensures that it is the
faulty set which is tripped leaving the healthy sets unaffected.

For technical information and more detailed description see leaflet.

3. TEMPERATURE MONITORING (Sheet 3).

A temperature monitoring equipment is mounted on each door of the

cubicle and shown on circuit diagram sht.3.

Each channel has provision for an input from a 3 wire 100 ohm
platinum resistance temperature detector and detection of 2
temperature levels: an alarm level at which a warning signal is
passed to the remote alarm annunciator (TCM) and a trip level at
which a shutdown instruction is given to the T.C.M.

The equipments receive their supply (24 volts D.C.) from the
appropriate gas turbine starter battery.

For details of the temperature monitors see Rochester instruction

manual.

4. SYNCHRONISING (Sheet 2)

A manual synchronising facility is included on the control panel.

The check synchroniser unit (FYC42) receives its running supply

from one of two sensing transformers VT3 or VT4 situated either
side of the bus section circuit breaker. The generator to be
synchronised is selected by moving the synch selector switch to the
appropriate position. Observe the running voltmeter and frequency
meter to ensure the availability of a running supply.

Synchronism is indicated when the synchroscope pointer is

practically stationary at the scale mark and the synchronising
lamps are dark.

Continued....
 The manoeuvring of the generator voltage and speed is in the hands
of the operator but the output circuit breaker cannot be closed
until the check synchroniser permissive signal is given.

If the 6 . 6 kV busbars are 'dead' and therefore no running supply to

the check synch. is available the dead busbar relays DBRA , DBRB and
DBRC are de - energised . The normally closed contacts in each
generator C.B. closing circuit allow the appropriate C.B. to be
closed without reference to the synchroniser unit . Again reliance
is placed on the operator to ensure generator speed ( frequency) and
volts are correct.

0^
 Component List

for

Two Generator Control Suite

Supplied to

GEC Large Machines Ltd.

for

Ruston Gas Turbines

fpr

Hamilton Bros, Duncan Field

S/0 03278501
 Device Description GEC Ordering Manufacturer/
Reference Reference Supplier

AVR gt Automatic Voltage Regulator REP/K5754-A2 GEC Industrial

Type C10/120 B4 Controls Ltd.,

MAVT Motorised Auto Volts Trimmer

Comprising:-

Auto Volts Potentiometer 500 ohm RE4/T64051-4

Motorised Unit RE4/T64050-3

HCU Hand Control Unit DL 3116728

HCST Hand Control Supply Transformer RE4/T97057-10

MHR Motorised Hand Regulator RE4/T97305-13

Hand /Auto/ Selector Switch RE4/T88061-23

Switch

HAC Hand / Auto Contactor i RE4/T84048-1

Compounding C.T. i' K3057506-6

EXC Excitation Contactor j K2985279-23

Watford Ref . (UCA3 Latched)

Auxiliary Contacts for above

Watford Ref . 60940-3

FV200 OV /UV Unit PL2986651-A1

LOR Lockout Relay Timer RE4/T87019-7

r FV223 DFR Diode Failure Detector REP/K5043-Al

Ref. FV223 Bi

Shunt Resistor for above GP6-4

Resistor Wirewound 0.23 ohm +10% , 120W.

Exciter Field Resistor GP6-22

Ballast Wirewound 7.5 ohms, +10%, 150W.

Field Resistor GP6-22

Discharge Wirewound 7.5 ohms, +10%, 150W

HFMR Hand Follow Up Meter Relay RE4/T91184-11

TR Timer Relay RE4/T87019-15

TPR Timer Pilot Relay RE4/T84048-1

CS Check Synchroniser REP/K4869-Al

T Type FYC 42
 Device Description GEC Ordering Manufacturer/
Reference Reference Supplier

DFPR1 Control Relay 24V D.C. Coil - Telemecanique

DFPR2 Ref. CA2 DN222BW Ashford.

Clip on auxiliary contacts for

DFPR11
Ref. LAl-D22

DBRA Control Relay AC 11OV, 60Hz.

DBRB Ref. CA2-DN122F
DBRC

Generator Voltmeter Moving Iron - Walsall

Volts Celsa Quadrant Scale Electrical
Scaled 0-8kV to read Walsall.
6.6kV with 110V 60Hz applied
Fed from 6.6kV/110V 60Hz. V.T.
Ref. EQ96S (Tropical Version)

Generator Ammeter Moving Iron

Current Celsa Quadrant Scale
Scaled 0-500A . F.S.D. 1 . 25 Amps.
Supplied from 400/1 C.T
Tropical Version

Voltmeter Selector Switch 3 Phase PR10 8351 A4 GEC Industrial

Selector E30PM Controls Ltd.,
SW.

Generator Celsa Type FA96S Moving Coil - Walsall

Frequency Frequency Meter with integral Electrical
electronic convertor Walsall.
Scaled 55-65Hz.
Supply 11OV, 60Hz.
Ref. 432.0011

Generator Celsa Type DQ96S

Load Electro Dynamic Wattmeter
Suitable for a 3 Phase 3 Wire
Balanced Load
Supplied from a 6.6kV/IIOV
3 Phase 60Hz. V.T.
C.T Ratio 400/1
Scaled 0-4.5MW
Tropical Version

Excitation Voltmeter Moving Coil

Volts Celsa Type PQ96S Quadrant
Scale. Scaled 0-100 Volts
Direct Reading
Tropical Version.

Excitation Ammeter Moving Coil

Current Celsa Type PQ96S Supplied from
a 60mV Shunt.
Scaled 0-10 Amps.
 Device Description GEC Ordering Manufacturer/
Reference Reference Supplier

Shunt for Excitation Current Walsall

Ammeter Electrical
60mV 10 Amp Walsall.
Celsa.

Diodes Silicon Rectifier Diode MED,

Dl-D4 (Gen 1) Tpye SJ1003-F Lincoln.
Dl-D4 (Gen 2)

Running Volts Voltmeter Moving Iron Walsall

Celsa Type EQ96S Quadrant Electrical
Scale . Scaled 0-8kV Walsall.
Fed from 6.6kV/11OV, 60Hz.
V.T. To read 6 .6kV with
11OV, 60Hz. applied
(Tropical Version)

Running Frequency Meter Moving Coil

Frequency Celsa Type FA96S Quadrant
Scale. With Integral Electronic
Convertor Scaled 55-65Hz.
Supply Volts 11OV, 60Hz.
Ref..432-0011.
(Tropical Version).

Synchroscope Electrodynamic Synchroscope

Celsa Type SQ96S/2
Incoming & Running Supplies
11OV, 60Hz.
To be used with Synchronising
Lamps - Lamps dark at
Synchronism. Complete with
Resistor Box (Tropical Version)

T Sycnhroscope Signal Lamp Clear Lens Arcolectric

Lamps Arcolectric Ref. No. SL102 Switches
West Molesey.

Pygmy Lamps for above

200/260V, 15W

Temperature 12 Way Temperature Monitor Rochester

Monitor Type TM 2482 Instrument
With:- Systems
3 Triple RTD Detector Modules Crayford.
to accept up to 9 active inputs
Input 0-2000C with
3 wire 100 ohm Platinum RTD's.
 Description GEC Ordering Manufacturer/
Device
1 Reference Supplier
Reference

1 Blanking Plate for Unoccupied

Rack Positions
1 Meter Common Service
Module for Digital Indication
of Point Temperatures and Set
Points, Common Alarm and Trip
Relays are accommodated in this
Module
System Power 24V D.C. from
Nickel Cadmium Battery

202-254 lwyn
Resistor Metal Oxide
Bedlington.
100 ohm, +2%, 0.5W

PR10-2254-A4 GEC Industrial

Local/ Remote Selector Switch, 2 Position
EP72MMC Controls Ltd.,
Switch Lockable in both positions
Ronis Key No. 455

Selector Switch PR10-2252-A4

Compounding
E30PM
Switch
In/Out

witch Double Pole with K Electric

Cubicle and
integral Neon Indicating Lamp London N9.
Generator
Anti- Ref. S232ALM
Condensation
Heater
Switches.
axheat
Cubicle ubular Heater
Liverpool.
Anti- 60W, 255V, Single Phase 60Hz.
Condensation
Heaters.
82120-101 GEC Fusegear
F4-F8 , Fuse Cartridge, 2 Amp
Liverpool.
F12-F14, Ref. NS2
F19, F20,
F24-F28,
F32-F34, F39,
F40, F44-F47

Fuse Cartridge, 4 Amp 82120-102

F9-Fll,
F29-F31, Ref. NS4
F41-F43,
F49, F51

Fuse Cartridge, 6 Amp 82120-103

Fl-F3,
F21-F23, Ref. NS6
F53-F56

Fuse Cartridge, 10 Amp 82120-104

F17, F37,
F48, F50 Ref. NS10

Fuse Cartridge, 16 Amp 82120-105

F18, F38
Ref. NS16
 GEC Ordering Manufacturer/
Description Supplier
Device Reference
Reference

82120-106 GEC Fusegear

F15, F16, Fuse Cartridge, 20 Amp Liverpool.
F35, F36, Ref. NS20
F52
PR10-1203 -R13 GEC Industrial
Excitation Control Switch Controls Ltd.,
E30PL
With Stayput and Spring Return
Close /N/Trip
V15SA10
Circuit Indicating Lamp . Red Lens
Breaker Open,
AVE. Tripped
to Hand,
Diode Failure
15SA20
ndicating Lamp. Green Lens
Circuit
Breaker Open
Z3XD1
Lamp Holder for above
WDL024
Filament Lamp for a b o ve
24/30V, 2W.
PR10-1202
Circuit Control Switch
-R12-E30PL
Breaker With Spring Return
C/N/T,
Governor
Raise / N/Lower,
Auto Volts,
Raise/ N/Lower,
Nand Reg.
Raise / N/Lower
4AA03
Lamp Test , Pushbutton Black
Diode Failure
-Relay Reset
ZlABl
Contact Block for above
With 1N / 0 and 1N / C Contacts.
 DRAWING LIST

INSTRUMENTATION AND A.V.R. CONTROL SCHEME RE1 / C15202 SHEET 1 ISSUE E

SYNCHRONISING SCHEME RE1 / C15202 SHEET 2 ISSUE E

TEMPERATURE MONITORING AND 24V D.C. RE1/C15202 SHEET 3 ISSUE E

CONTROLS
GEC Industrial Controls Limited
Technical Manual 78997
AVR TYPE CiO/120-B3 & B4 WITH
HAND CONTROL HC12
 Contents Page 1.
Issue 4/84 TM 78997

CIO/120-B3 & B4 AUTOMATIC VOLTAGE REGULATOR WITH HC12 HAND CONTROL

LIST OF CONTENTS

SECTION 1. GENERAL

1.1 Introduction.
1.2 Summary of Components.

SECTION 2. TECHNICAL DESCRIPTION

2.1 Principles of Operation.

2.2 Description of Circuit.
2.2.1 Voltage Sensitive Circuit.
2.2.2 Amplifier and SCR Drive Circuit.
2.2.3 Silicon Controlled Rectifier Circuit.
2.2.4 Stabilizing Circuit.
2.2.5 Parallel Operation.
2.3 Hand Control with Null Balance - HC12.

SECTION 3. INSTALLATION

SECTION 4. INITIAL ADJUSTMENTS AND COMMISSIONING

4.1 Preliminary Checks.

14.2 Hand Control.
4.3 Auto Control.
4.4 Null Balance Circuit HC12.
4.5 Load Tests.

SECTION 5. OPERATING INSTRUCTIONS

5.1 Bringing the Regulator Unit into Service.

5.2 Taking the Regulator out of Service.

MAINTENANCE

SECTION 7. FAULT FINDING

7.1 Fault Finding Guide.

7.2 General Notes on Checking Components.

SECTIO N 8. COMPONENTS LIST AND RECOMMENDED SPARES

8.1 C10 /120B3 & B4 AVR.

8.2 HC12 Hand Control Unit.

SECTION 9. DRAWING LIST .

 Section 1, Page 1.
Issue 4 /84 TM 78997

SECTION 1 - GENERAL

1.1 Introduction

The C10/120-B3 AVR is a static automatic voltage regulator providing power to the
field of an exciter. The power supply to the AVR is derived from an external
constant voltage supply which is usually either a shaft driven permanent magnet
generator or a reliable separate supply voltage . The regulator is set up in the
factory to suit the particular power supply being used. The P.M.G. is normally
driven from the same shaft as the main generator and exciter. The excitation
scheme for a brushless exciter is illustrated in Figure 1.

Pi g. l - A Brush less Sy stem £or a Separ<arte Excitation System

The CIO/120-13- AVR is primarily intended for 3 phase sensing applications but it
i3 possible by setting links in the AVR, to make it suitable for a single phase
sensing signal. Should the C10/120-B- AVR be required for a single phase
sensing application these links will he set in our factory and a special
external connection diagram issued.

The C10/120-B- AVR holds the generator output voltage constant to within +1% of
set voltage under steady state conditions with zero compounding. An accuracy
of + 0.5% is possible for some applications.

Voltage recovery following load changes is rapid and only limited by the
characteristics of the machines. Provision is made for quadrature droop
compounding to enable generators to operate in parallel, or in parallel with the
public supply. Additional. units can be provided to modify the control of the
AVR to provide such features as exciter field current limit., power factor control,
7i or volts per cycle control under variable speed conditions.
 Section 1, Page 2.
Issue 11/82 TM 78997

The HC12 hand control circuit provides a separate excitation supply using a
variable transformer and rectifier. In addition it also provides a null
balance circuit designed to ensure smooth change-over from Hand to Auto and
from Auto to Hand control.

1.2 Summary of Equipment

The equipment supplied is as follows:-

1. Type ClO/120 Automatic Voltage Regulator.

2. External Auto-Volt Trimmer.
3. Hand Control Panel HC12.
4. Hand-Auto Changeover Switch.
5. Hand Control Variable Transformer.
6. Supply Transformer for Hand Control Circuit.
7. Null Balance Meter.

On certain contracts the following additional items may be supplied.

1. Excitation on-off contactor.

2. Quadrature droop compounding current transformer.
3. The hand and/or auto volt controls can be motor operated.
4. A range of electronic panels to modify the control of the regulator.

0
 Section 2, Page 1.
Issue 4 /84 TM 78997

SECTION 2 - TECHNICAL DESCRIPTION

2.1 Principles of Operation

Refer to the simplified diagram shown in Fig.2.

A voltage proportional to generator voltage is applied to the reset and reference

circuit where it is rectified and T-mixed with a zener diode reference voltage.
The difference results in an error output which is amplified and then used to
control the SCR drive circuit. This circuit gives a pulse output , the leading
edge of each pulse being advanced or retarded according to the value of the error
signal.

The pulse from the SCR drive circuit switch on the silicon . controlled rectifiers;
By controlling the point in its positive half cycle at which each SCR is switched
on, the average exciter field voltage is adjusted to the correct value.

POWER
SUPPLY

RESET AMPLIFIER EXCITER

SENSING AND AND SCR CIRCUIT
SCR DRIVE FIELD
VOLTAGE REFERENCE
CIRCUIT CIRCUIT

Fig . 2 - BlockDiagram of Type C10/120-`B'- AVR

 Section 2, Page 2.
Issue 11/82 TM 78997

2.2 Description of Circuit

Reference should be made to the circuit diagrams and external connection diagram
supplied with the equipment and specified in Section 9.

Most of the control circuit is mounted on three printed circuit boards situated
inside the box. The power diodes and thyristors are mounted on fins.

2.2.1 Voltage Sensitive Circuit

The three phase sensing voltage is brought to AVR terminals 5,6 and 7. It is
then applied via resistors to the primaries of transformers Ti and T4. The
output from the secondaries of Tl and T4 is rectified by diodes D18-D23 and a
d.c. voltage is developed across resistor R4, potentiometer RV1 and the external
auto-volt trimmer. After being smoothed by R5 and Cl, this voltage is T-mixed
with the reference voltage developed across Zener diode D25 and applied as an
error voltage to the input of the integrated circuit amplifier.

2.2.2 Amplifier and SCR Drive Circuit

The error voltage is amplified by integrated circuit ICI and the output is used
to control transistor TR1 which in turn controls the rate of charge of capacitor
C9 (via resistors R13-R16 and Transistor TR2). When the voltage across C9
reaches the trigger level required by unijunction tansistor TR3 the capacitor
discharges through the unijunction transistor and transformer T3. This produces
the thyristors.
a pulse on both secondary windings of T3 suitable for firing

The firing circuit is synchronised to the supply frequency by connecting capacitor

The supply voltage
C9 to a supply voltage that falls to zero twice per cycle .
comes from transformer T2, rectifier DlO-11 and Zener diode D28.

In order to ensure that the unijunction transistor current falls below thedvalley
level after the thyristor has fired, the amplifier output voltage is group e
the end of each half cycle by transistor TR4.

2.2.3 Silicon Controlled Rectifier Circuit

Two SCR's and two diode rectifier's are connected in a full wave rectifying
arrangement. The field supply for the a.c. exciter is derived from the P.M.G.
supply which is brought into the AVR on terminals 3 and 4. On one half cycle the
current flows through SCR1, the field circuit of the a.c. exciter and D16. On
the reverse half cycle the path is SCR2, the field circuit and D15. Rectifiers
D15-D16 allow the exciter field current to circulate during the period when the
SCR's are cut off.

2.2.4 Stabilising Circuit

During transient conditions, circuit R11, RV3, RV4, C2a-b, C4 provides negative
feedback to the input of the amplifier. The degree of stabilising is pre-set by
potentiometers RV3 and RV4.
Issue 11 / 82 TM 78997 Section 2 , Page 3.

2.2.5 Parallel Operation

For quadrature droop compounding a current transformer must be fitted to line C

of the generator output. This will give an output which is brought to the AVR
terminals 10 and 11. Here it is applied across potentiometer RV2 and injected
into transformers T1 and T4. This modifies the reset voltage in such a way as
to cause the generator to take its share of reactive M. However, this
introduces a small voltage droop with reactive load.

2.3 Hand Control with Null Balance - HC12

This circuit allows smooth changeover from auto to manual and vice versa. The
HAND and AUTO . output voltages are smoothed and compared by means of a null balance
meter. When the voltages are equal , changeover in either direction will be smooth.
The HC12 unit combines all the required circuitry for null balance as well as the
Hand Control rectifier.

When the changeover switch is set at HAND, the excitation is controlled manually
using the hand control variable transformer . The supply from the P . M.G. is taken
via an isolating transformer to this variable transformer , and then via the HC12
unit to the field of the a.c. exciter.
 Section 3. Page 1.
Issue 11/82 TM 78997

SECTION 3 - INSTALLATION

3.1 Mounting

When the AVR is supplied without a protective cover it is intended for mounting
inside a cubicle or other protected enclosure. The following points should be
noted:-

1) The AVR should be mounted in a well ventilated position not close to or above
hot equipment. The cubicle itself should be ventilated so that the temperature
of the air surrounding the AVR is not more than 100C. higher than the general
ambient.

2) The unit should be mounted vertically - i.e. with the axis of the
semi-conductor heat sinks vertical.

3) The unit should be mounted in a reasonably accessible position and in

particular the preset potentiometers should be readily accessible for adjustment.

4) Resilient mounts should be fitted if the location is subject to severe vibration.

5) Where corrosive gases are present in the atmosphere it is recommended that bare
conducting parts such as soldered joints should be painted with silicone varnish
to prevent corrosion.

3.2 Wiring

The AVR should be wired in accordance with the external connection diagram supplied
with the equipment. When a parallel operation CT is fitted particular attention
should be paid to ensuring that it is connected in the correct phase, that the
phasing of its primary and secondary connections are correct and that terminals 5,6
and 7 on the unit are connected to the correct phases as shown on the diagram.

The connections to the remote voltage trimmer and parallel operation CT (where
fitted) should be kept as short as possible and should, as far as possible, not be
grouped in a loom with main power cables. In installations where the leads to the
voltage trimmer are long , or where pick-up from power circuits is likely, these
leads should preferably be wired in twin screened cable. The screen should be
isolated from earth (440V grade) and should be connected to terminal 9 of the AVR.

Where the remote voltage trimmer is to be mounted an extremely long distance from
the AVR (e.g. in another building) then it is recommended that a motorised voltage
trimmer unit is fitted locally with remote control from raise/lower pushbuttons.

3.3 Earthing

The AVR box should be soundly earthed.

3.4 Warnings

1) The AVR and associated equipment should not be subjected to a flash test.
Insulation resistance may be checked by connecting all terminal block terminals
together and meggering to earth with a 1000 volt megger. Individual terminals
must not be meggered.

2) The secondaries of all current transformers must be shorted out if current

r' injection tests are carried out on the busbars.
 Section 4 . Page 1.
Issue 11 / 82 TM 78997

SECTION 4 - INITIAL ADJUSTMENTS & COMMISSIONING

DANGER

When this equipment is energised there are exposed " live" connections. When
adjusting the controls as detailed below CARE MUST BE TAKEN TO AVOID CONTACT
WITH THESE " LIVE" PARTS.

4.1 Preliminary Checks

1. Check that the equipment has been connected up exactly as shown on the
external connection diagram supplied with the equipment.

In particular it is important that:-

a) Connections to terminals 5,6 and 7 are correctly phased.

b) The compounding transformer is connected in the correct phase. It is

strongly recommended that the phasing of this transformer should be
checked both on the primary and secondary sides. Due to different
conventions , the compounding current transformer primary may not be
connected as shown on the AVR external connection diagram. If this
is the case the correct secondary connections may also differ.

To check that the connections are correct the rule is that if the CT
primary connection nearest to the generator star-point is the same as
that shown on the AVR diagram then the secondary connections should be
exactly as shown on the AVR diagram . If, however , the CT primary
connection nearest to the generator star point is the opposite of that
shown on the AVR diagram then the CT secondary connections should also
be reversed.

2. Check that all fuses are in position.

3. Set the remote trimmer ( if fitted) to mid position.

4. Check that the correct links are used on the front of the regulator.

a) Reset Voltage Links

The AVR is suitable for accepting either a generator voltage of 380/450

volts or a voltage of 100/120 volts from a potential transformer. For
380/450 volts input the links MUST BE OUT. For 100/120 volts input the
links MUST BE IN.

b) PMG Voltage Link

The AVR will accept a supply voltage on terminals 3 and 4 from a PMG or a
separate a.c. supply . Three links are provided to cover a range of:-

(1) 80 to 115 volts.

(2) 115 to 165 volts.

(3) 165 to 240 volts.

Ensure that the correct link is made.

 Section 4 , Page 2.
Issue 11 /82 TM 78997

c) PMG Frequency

Set the links to correspond to the normal frequency of the supply on

terminals 3 and 4.

( 1) 40 Hz. to 75 Hz. - No link required.

(2) 75 Hz. to 130 Hz. - Link "75 - 130 Hz."

(3) 130 Hz. to 220 Hz , Link " 130-220 Hz."

(4) 220 Hz. to 400 Hz. - Link "220-400 Hz."

Ensure that the correct link is fitted.

5. Set the stabilising controls RV3 and RV4 to their mid - position.

4.2 Hand Control

1. Switch the HAND-AUTO switch to HAND.

2. Set the hand control variable transformer to minimum.

3. If an excitation switch is fitted , switch to ON.

4. Run the set up to normal speed.

5. Check that the output voltage of the PMG (if fitted ) is correct.

6. Adjust the hand control to give normal generator voltage.

7. At a later stage the hand control should be checked over the full generator
load range.

DANGER

When this equipment is energised there are exposed "live " connections on both the
AVR and the HC12 hand control unit . When adjusting the contro l s as da ta' 1e d below
CARE MUST BE TAKEN TO AVOID CONTACT WITH THESE " LIVE" PARTS.

4.3 Auto Control

1. Set the auto - volt trimmer to the centre of its range.

2.\ Switch to AUTO control and set the auto-volt trimmer to give the correct
generator voltage.

3. 'Set the stabilising controls to give good stability.

There are two stabilising potentiometers which need to be set up, one of which
is a time constant ( RV4) and the other is an amplitude control (RV3).

These must be set up to ensure that no continuous oscillations of the generator

voltage occurs and that the response of the generator voltage following a load
Setting up is most easily carried out by
change is free from undue overshoots .
displaying the generator voltage waveform on an oscilloscope . Although the
d• of the meter may
oscillations can normally be seen on a voltmeter t h e aaLpii.g
greatly affect the results obtained.
 Section 4, page 3.
Issue 11 /82 TM 78997

a) Initially set RV3 and RV4 each to position 5.

b) Run the generator at normal speed on no-load.

c) Turn RV3 anticlockwise until the generator output voltage just becomes
unstable. Now turn RV3 clockwise by two positions (e.g. 3 to 5) from the
position of instability.

This procedure should give, approximately the correct stability but to obtain
optimum results the response to load changes should be examined on an
oscilloscope. Turning RV3 clockwise will increase the damping but turning it
too far may cause a slow overdamped response with fast oscillations. The ideal
response should give the fastest recovery with not more than one overshoot.

If the stability cannot be adjusted satisfactorily with RV3 alone, try

adjustingRV4.

4. Set the range of the auto-volt control so that the mid-position corresponds to
the required operating voltage. This condition is obtained by adjustment of
potentiometer RV1.

4.4 Null Balance Circuit HC12

The null balance. circuit should be set up as follows:-

1. Set the generator voltage to give normal volts on Hand Control.

2. Without adjusting the Hand Control, switch to AUTO, and re-adjust generator
voltage to normal.

3. Adjust potentiometer RV1 on the HC12 null balance unit to give zero reading
on the null balance meter.

4. Switch to HAND control and check that the change in generator output voltage
is at a minimum. If necessary re-adjust RV1 on the HC12 unit to obtain the
best possible results.

5. Adjust the auto-volt trimmer in the direction necessary to give zero reading
on the null balance meter: if the: pointer is at, the left hand side of zero,
r14 the AVR setting is high: if at the right hand side the hand control setting
is high. Note that there will be a considerable time delay in the response
of the meter to large changes in the auto-volt trimmer setting when changing
from Hand to Auto. It is desirable to adjust the trimmer in small steps,
pausing between settings. Due to the sensitivity of the AVR when in open
loop it can be difficult to keep the balance meter pointer steady at zero.
However, it is not necessary for the pointer to be in the zero position
before operating the changeover switch as long as the auto-volt trimmer is
in a position such that a small movement of the trimmer is one or the other
direction will swing the balance meter pointer through the zero position.
Check that the change in generator voltage on switching to Auto control is
at a minimum, although small change in voltage should be expected.

NOTE - This test can be carried out with the generator on no-load but is best
done under load conditions. A small change in excitation must be
expected on changeover from Auto to Hand control. under other load
conditions. When changing over from Hand to Auto control allow a few
seconds for the AVR output to stabilise.
 Section 4 , Page 4.
Issue 11 / 82 TM 78997

4.5 Load Tests

1. Regulation

With the excitation in auto control application of load should have very
little effect on the generator voltage with potentiometer RV2 in the AVR
Under these
unit set fully anti-clockwise ( i.e. compounding ineffective ).
conditions regulation over the full load range should be within + 1%.

2. Compounding for Parallel Operation

To achieve satisfactory kVA sharing , quadrature droop compounding control RV2

in the AVR should be set to give the generator voltage / load characteristic
similar to the sets with which it is required to parallel.

For correct operation of the compounding circuit the phasing of the voltage
and current transformers must be correct. The phasing may be checked in two
ways:-

a) Apply a lagging power factor load to the generator running singly,

isolated from other machines or the grid . The generator terminal voltage
should fall . A rise in voltage indicates incorrect phasing and the
compounding CT connections should be reversed.

b) Run the generator on hand control in parallel with the grid or with
other machines . Adjust the auto-trimmer so that the regulator gives an
output of approximately 40 volts at terminals 1 and 2. Turn the hand
control to increase excitation and cause the generator power factor to
become more lagging. This should result in the regulator output
decreasing . An increase indicates that the connections to the compounding
CT are incorrect . The point when the incorrect connection has been made
should be located by checking wiring against the external. connection
diagram. Normally it will be found that the connections should be
reversed to make the phasing correct.
 Section 5. Page 1.
Issue 11/82 TM 78997

A SECTION 5 - OPERATING INSTRUCTIONS

5.1 Bringing the Regulator into Service

a) Run the generator up to speed , and set the voltage to the nominal value,
using the hand control variable transformer.

b) Adjust the auto-volt trimmer to give a balance on the null balance meter.
( For additional information on the balancing method see section 4.4.5).
If no null balance circuit is included , set the auto volt control to its
mid position.

c) Switch to AUTO control and trim the auto-volt trimmer to the required
setting.

d) Load the generator as required . If this involves parallel operation, the

auto-volt control must be adjusted to bring up the reactive load taken by
the generator in the same way as the governor controls are adjusted to
bring up the kW load.

5.2 Taking the Regulator out of Service

a) Remove the load from the set.

b) Adjust the balance control to give a balance on the null balance meter.

c) Switch to hand control and trim the control to give the required
generator voltage.
 TM 78997 Section 6, Page 1.
Issue 11/82

1y
SECTION 6 - MAINTENANCE

6.1 General
. However, regular
Little maintenance is required on this type of equipment
t
inspection is the best assurance against serious faults. I conditoot possible to
lay down a strict routine as this must depend on operating
As a rough guide, it is recommended that equipment operating
personnel available .
under normal duty should be inspected at three monthly intervals.

6.2 Routine Inspection

The following checks are suggested:-

These should be carried out with the equipment switched off and isolated.

Check that all external connections are secure, especially in the terminal block.
Check all leads to the AVR. Check the external voltage trimmer and leads.
. The SCR and diode cooling
Examine internal connections for looseness or fraying
, check the fuses are
fins should be blown out to remove any accumulations of dirt
of correct rating and secure fit.
 Section 7, Page 1.
Issue 11/82 TM 78997

SECTION 7 - FAULT FINDING

DANGER

When this equipment is energised there are exposed "live" connections. When
adjusting the controls as detailed below CARE MUST BE TAKEN TO AVOID CONTACT
WITH THESE "LIVE" PARTS.

If trouble is experienced in Auto control the first thing to do is to check

operation in Hand Control. If satisfactory operation is obtained in Hand Control.,
but not in Auto Control, then the fault is most likely in the AVR unit.

Several means of detecting the fault may be available - e.g. visual examination,
continuity and resistance checks, component checks, voltage checks, etc.

See the following fault finding guide and general notes on checking components.

7.1 Fault Finding Guide

SYMPTOMS CHECKS

l., Band Control

a) The generator will not : 1. Fuses in PMG supply.

excite in hand control. 2. Connection to hand control unit.
3. Continuity through hand control and
exciter field circuit.
4. Hand control rectifier.

2. Auto Control

a) The generator will not 1. Connections to AVR terminals 1,2,3, & 4.

excite in auto control. 2. Rectifiers D15-16 and connections.
3. SCR's 1 and 2 and connections.
4. Continuity from PCB to SCR gate circuits.
5. Supplies from T2 to PCB.

b) Voltage goes too high 1. Sensing supply is present on AVR

-p in auto control. terminals 5,6 and 7.
2. Connections to terminals 8 & 9 from
auto - volts trimmer.
3. SCR's 1 and 2 for forward conduction
without trigger pulse.
4. Continuity through the reset circuit.

7.2 General Notes on Checking Components

Capacitors can be checked by a normal universal test set with a resistance range
of 1000 ohms or higher. At least one side of the capacitor should be disconnected
from the circuit. Use the test set on highest resistance range. On touching the
test set leads across the capacitor the pointer should swing towards zero ohms and
then rapidly come back to the infinity reading. Repeat this test several times,
reversing the polarity of the test set leads between each test or discharging the
capacitor between the tests. If the pointer does not swing transiently towards
zero ohms, or if the reading settles down to a low value of ohms, then the
capacitor is faulty.
 Section 7, Page 2.
Issue 11 /82 TM 78997

Rectifying diodes can also be checked by a universal test set with a resistance
range. It is necessary to disconnect at least one ofthe d.c. connections to the
rectifier but the a.c. connections can be left on. Because of the non-linear
characteristics of a silicon diode it is not possible to state what the forward
and reverse resistance should'be. However in general, the resistance in the
reverse direction (against the normal flow of current) should be expected to be
at least 100 times greater than in the forward direction. If a fault is found
in the rectifier unit each of ttie individual elements should be tested separately
to determine which element or elements are faulty.

S.C.R's may be checked as follows:-

Disconnect the cathode lead. (This:'is the thick flying lead). The anode to
cathode resistance should be very high in both directions, greater than about
-50,000 ohms.

NOTE:-

This check will not detect all faulty SCR's: replacement with a spare is necessary
In cases of doubt.

WARNING

If an SCR/diode is changed the cooling fin must be carefully cleaned in the region
where it is in contact with the component, taking care to remove varnish
accumulations and ensure that the contact area is perfectly smooth, otherwise the
heat conducting properties between component and fin will be adversely affected.

Transformers etc., can be checked by measuring the continuity and resistance of

their windings. The transformer ratios can be checked by a voltmeter when in
operation.

To check for suspected faults in encapsulated printed circuit units simply

interchange with spare units, taking care to ensure that the correct type is used
and that the leads are replaced on the appropriate terminals.

r
^ Issue 4/84 TM 78997 Section 8, Page 1.

8. COMPONENTS LISTS AND RECOMMENDED SPARES

8.1 C10/120-B-Automatic Voltage Regulator

ORDERING UNIT RECOMM. AVR

DEVICE DESCRIPTION
REF QTY SPARES FORM
REF

Printed Circuit Board Assembly 650-23X2160-PlO 1 .1

A
Printed Circuit Board Assembly 650-23X2161-P10 1 1
B
P.C. Board Assembly 650-23X2162-PlO 1 1
C
Variable W/W. 1.0k ohms. +10%. 1W 64405/331 1 1
RV1
Variable W/W. 10 ohms. +10%. 2.9W 64475/221 1 1
RV2
Variable W/W. l0k ohms. +10%. 1W 64405/391 1 1
RV3
Variable W/W. 25k ohms. +10%. 1W 64410/641 1 1
RV4
RE4/T78087-1 1 1 -B3
D5/SCRl Diode/Thyristor MEDL PM5 A7QG.
RE4/T78087-1 1 1 -B4
D5/SCR1 Diode/Thyristor MEDL PM5 A8G-l
RE4/T78087-2 1 1 -B3
D16/SCR2 Diode/Thyristor MEDL PM54 A7QG
RE4/T78087-4 1 1 -B4
D16/SCR2 Diode/Thyristor MEDL PM54 A8G-1
Reset Transformer RE4/T97607-1 2
T1,T4
Auxiliary Supply Transformer RE4/T97152-1 1
T2

NOTE - All devices are common to both Form B3 and Form B4 AVR's unless stated
otherwise.

8.2 HC12 Hand Control Unit (with Null Balance)

W/W Mica Card 34 ohms. +10%. 80W 62901/301 1 1
R1
W/W Resistor. 1.2k ohms. +5°1,. 9W 62302/333 1 1
R2
R3,R5 W/W Resistor. 1.2k.ohms. +5%. 12W 62352/333 2 1

W/W Resistor. 1.0k.ohms. +5%. 9W 62302/327 1 1

R4
Metal oxide. 2.7k ohms. +5%. 2W 60402/357 1 1
R6"
Metal Oxide. 470 ohms. +5%. 2W 60402/303 1 1
R7
W/W Resistor. 1.8k ohms. +5%. 3W 62550/345 1 1
R8
Paper Capacitor. 4uF, +20%, 800V d.c. 68553/105 1 1
Cl
C2,C3 Capacitor 1000uF. 100V. 69299/316 2 1

Bridge Rect. Westinghouse 14.6A 80OV. RE4/T71004-1 1 1

D1
D2,D3 Diode Type 15923 71078/350 2 1

Diode MEDL. SL803F. 800V. K2564170-43 2 1

D4, D5
Westinghouse Suppressor C125IOlA K3110524-22 1 1
D6
W/W Potentiometer 250 ohm. +10%. 3W 64470/307 1 1
c RV1
0
u
 TM 78997 Section 8, Page 2
Issue 11/82

8.2 HC12 Hand Control Unit ( with null balance).

Ordering Quant. Recommended

Circuit per Spares.
Description Reference
Reference Unit

62901/301 1 1
R1 Wirewound Mica Card
34 ohms, +10% , 80watt

62302/333 1 1
R2 Wirewound Resistor
1.2k.ohm, +5%, 9watt

62302/327 1 1
R4 Wirewound Resistor
1.Ok.ohm, +5%, 9watt

Wirewound Resistor 62352/333 2 1

R3,R5
1.2k.ohm, +5% , l2watt

60402/357 1 1
R6 Metal Oxide Resistor
2.7k.ohm, +5%, 2watt

60402/303 1 1
R7 Metal Oxide Resistor
470 ohms, +5%, 2watt

62550/345 1 1
R8 Wirewound Resistor
1.8k.ohm , + 5%, l7watt

68553 / 105 1 1
Cl Capacitor - Paper
4 uF., +20%, 800V.d.c.

69299/316 2
C2,C3 Capacitor 1000!uF.,l00V.

RE4/T71004-1 1 1
Dl Bridge Connected Rectifier
14.6 amp, 80OV . Westinghouse

Diode type 15923 71078/350 2 1

D2,D3

Diode AEI Ref. SL803F , 800V. K2564170-43 2 1

D4,D5
K3110524-22 1 1
D6 Westinghouse Suppressor
type C125LOlA

64470/307 1 1
RV1 Wirewound Potentiometer
 /84 TM 78997 Section 9 , Page 1.
Issue 6

SECTION 9 - LIST OF DRAWINGS

9.1 Type CIO / 120-B3 & B4 AVR

Circuit Diagram. RE2/K5428

9.2 Hand Control

Type HC12 Circuit Diagram. RE3/K1119

 GEC Industrial Controls Limited
OWN Technical Manual 78994
LFV200 A3 OV/UV PROTECTION UNIT

r
 82 TM 78994 Contents , Page 1.
Issue 9 /

OVER / UNDER VOLTAGE PROTECTION UNIT TYPE FV200 A3

CONTENTS

1. INTRODUCTION.

2. CIRCUIT DESCRIPTION.

3. INSTALLATION & COMMISSIONING.

3.1 Mounting.
3.2 Wiring.
3.3 Earthing.
3.4 Warnings.
3.5 Initial Adjustments.

4. TESTING & FAULT FINDING.

4.1 Voltage Checks.
4.2 Fault Finding.

5. COMPONENTS LIST & RECOMMENDED SPARES.

5.1 Printed Circuit Board.
5.2 Other Components.

6. DRAWING LIST.
Issue 9/82 TM 78994 Page 1.

OVER /UNDER VOLTAGE PROTECTION UNIT

TYPE FV200 A3

1. INTRODUCTION

This relay is designed to energise at 110V. supply and trip out should the voltage
rise of fall beyond certain preset limits.

The circuit also includes a quadrature current sensing circuit which trips the
relay should the reactive component of the current rise above a preset level.

The relay incorporates a time delay circuit to avoid the relay tripping out
unnecessarily on transient changes.

The power consumption of the relay is about 10VA on the voltage sensing circuits,
and 2VA on the current circuit. The output is a change-over contact rated at
240V., 6A., a.c.

2. CIRCUIT DESCRIPTION

Refer to the equipment circuit diagram , or the simplified diagram Fig.l.

A 110V. signal between two phases of a generator is stepped down and rectified,
by transformer T1 and rectifier MR1. This d.c. signal is applied to a
transistorised sensing circuit.

Transistor VT2 conducts when its base voltage , taken from potentiometer RV2, is
more negative than its emitter voltage measured across zener diodes Z1 and. Z2.
Therefore , when the voltage applied across terminals 1 and 2 is above the low
voltage setting , VT2 will conduct: a voltage is in turn developed across R11,
turning on VT4 which in turn energises-RL1. The contact RL1/l picks up RL2 which
is connected across the 110V. a.c. input . When the voltage increases above the
high volt setting; the base of VTl is then more negative than the emitter and it
then conducts , which causes VT3 to conduct, which shorts out R11. This causes
VT4 to stop conduction , hence RL1 and RL2 drop out. Capacitor C4 and
potentiometer RV3 give a short time delay to transistor VT4 ensuring that RL1 and
RL2 remain picked up during sudden changes in supply voltage.

A IA. or SA . current signal taken from the third phase , is added to the a.c.
voltage before it is rectified. This addition makes negligable difference to
this voltage at unity power factor , as the vectors are in quadrature. As the
bower factor tends to lag or lead the current vector will add or subtract to the
voltage signal , causing the sensing circuit to trip. The current required to
trip the relay is set by links A - D.

3. INSTALLATION AND COMMISSIONING

3.1 Mounting

When the Voltage Protection Unit is supplied without a protective cover, it is

intended for mounting inside a cubicle or other protected enclosure. The
following points should be noted:-

a) The Voltage Protection Unit should be mounted in a well ventilated position

not close to or above hot equipment . The cubicle itself should be
ventilated so that the temperature of the air surrounding the Voltage
Protection Unit is not more than 100C higher than the general ambient.
Issue 9 /82 TM 78994 Page 2.

b) The unit should be mounted in a reasonably accessible position, and in

particular the preset potentiometers should be readily accessible for
adjustment.

c) Resilient mounts should be fitted if the location is subject to severe

vibration.

d) Where corrosive gases are present in'the atmosphere, it is recommended that

bare conducting parts such as soldered joints should be painted with silicone
varnish to prevent corrosion.

3•.2 Wiring

The Voltage Protection Unit
connection diagram supplied
attention should be paid to
and that the phasing of its
on the diagram.
should be wired in accordance with the external
with the equipment. When CT is fitted, particular
ensuring that it is connected in the correct phase,
primary and secondary connections are correct as shown

3.3 Earthing

The Voltage Protection Unit should be soundly earthed.

3.4 Warnings

The Voltage Protection Unit and associated equipment should not be subjected to a
flash test. Insulation Resistance may be checked by connecting all terminal block
terminals together and meggering to earth with a 1000 volt megger.

3.5 Initial Adjustments

DANGER - When this equipment is energised, there are exposed "LIVE" connections.
When adjusting the controls as detailed below - CARE MUST BE TAKEN TO AVOID
CONTACT WITH THESE "LIVE" PARTS.

1. Run the generator under hand control and set the voltage to nominal.

2. Reduce the time delay to zero and slowly decrease the generator voltage to
the required tripping voltage. Set RV2 so that relay RL2 just drops out.
Increase the voltage again and check that the relay picks up before nominal
voltage is reached.

3. 'Increase the voltage to the required ON tripping voltage and set the 0/V
potentiometer RV1 until the relay just trips.

4. Recheck the above two voltages again. Typical settings are +10% and -15%:
these values are normally set before the equipment leaves the factory.

5. Increase the time delay setting to that required for standard static
regulators: about 1 second is found to be sufficient. This time delay may
have to be increased if large machines are to be run up.
 Issue 9 /82 TM 78994 Page 3.

f 6. Set the current level by links A- D as detailed below:-

Links Amount Typical Level

a) C - D Large 70% FLC at zero pf.

b) B - D Medium 130% FLC at zero pf.
c) B - D & A - C. Low 250% FLC at zero pf.

Setting (b) is recommended for most applications: if large loads are to be

expected (i.e. in excess of Z pf. full load) change to connection (c).

7. Run the set under hand control in parallel with the grid or another machine,
and take up some load. Increase the excitation causing the power factor to
go lagging and note that the voltage across the terminals 13-9 increases.
If this voltage decreases, reverse the current sensing leads.

4. TESTING AND FAULT FINDING

DANGER - With this equipment there are exposed "LIVE" connections.

4.1 Voltage Checks

Apply a 110 volt, 50/60 Hz. supply to terminals 1 & 2, and measure the following
voltages:-

Test No. Wiring Point Voltage

1. 16-15 22V. +10% a.c.

2. 13-9 (13 +ve) +23.5V. +2V.d.c. (RL1&2 should be energised).
3. across Z1 & Z2 +9.5V. +10% d.c.
4. Check operation of relay RLl, varying the 11OV. a.c. supply.

4.2 Fault Finding

Fault Probable Cause

1. Relay fails to energise. a) RV1 or RV2 set incorrectly.

b) VT1 or VT2 failed S/C.
c) MTR3 failed 0/C.
d) Loss of supply. Check 4.1.

2.' Relay fails on over volt. a) VT4 failed S/C.

b) RL1 contacts welded.
c) Z1 or Z2 failed S/C.

5. COMPONENTS LIST & RECOMMENDED SPARES

The ratings of all dissipating components are approximately 75% if the manufacturer's
maximum ratings.
 Issue 8 /83 TM 78994 Page 4.

5.1 Printed Circuit Board (PL2986654-Al)

Component Ordering
Reference Description Reference

Resistors:-

R1, R2. Metal Oxide 27 ohms . + 2%. 0.5W. 60202/212

R3, R7. Metal Oxide lk ohm . + 2%. O.W. 60202/326
R4. Metal Oxide 2.2k ohm. +2%. O . W. 60202/350
R5. Metal Oxide 3.3k ohm. + 2%. O.W. 60202/362
R6, RIO. Metal Oxide 3.9k ohm. +2%. O.W. 60202/368
R8. Metal Oxide 8.2k ohm. +2%. O.W. 60202/392
R9, R13. Metal Oxide 470 ohms. +2%. O.W . 60202/302
Rll. Metal Oxide 4.7k ohm. +2%. O.W. 60202/374

Potentiometers:-

RV1 Wirewound 500 ohms; +10 %. 1.OW. 1RWJA-501L-64DF

RV2 Wirewound 2.5k ohm. +10%. 1.OW. 64410/502
RV3 Wirewound 25k ohms. +10 %. 1.OW. 1RWJA-253L-64DF

Capacitors :- ( Electrolytic, Aluminium , Etched Foil)

Cl, C2. 470uF . - 10% +50%. 63V. d.c. 69105/999

C3. lOuF. - 10% +100%. 35V. d.c. 69075/268
C4. lOOuF. -10 % +50%. 35V. d.c. 69075/292

Transistors:-

VT1, VT2. Mullard Type ACY21. 75001/102

VT3, VT4. Texas Type 2N697. 75370/252

Rectifiers & Diodes Etc.:-

MR2, MR3. Rectifiers Texas Type IS923. 71078/350

Z1, Z2. Zener Diode. AEI Type VR475 -F. 72299/277
Z3,' Z4. Zener Diode. Mullard Type B2Y95C24 . 72240/560
RL1. Relay . Eng. Ind. Corpn.
Type AEI-ILA / G3 (MS)
1 N/0 Contact . 12V Coil. 86021/105

eft,
 Issue 8/83 TM 78994 Page 5.

5.2 Other Components

Component Ordering
Reference Description Reference

MR1, MR4. Rectifier , Westinghouse Type S4MBT7. 71720/140

RL2. Relay, Londex Ltd . TOP relay , 2C/O contacts.

48V d.c. coil . Ref.TOP/20. RE4/T86215-3

T1. Transformer. Y296709.1-1

T2. Transformer. Y2967091-2

R14. Resistor , Wirewound, lk ohm , + 5%, 9W. 62302/327

O"N It is recommended that one complete unit is kept as a spare ordered under parts
list reference PL2986651-A1.

6. DRAWINGS

Circuit Diagram DZD94423.

Simplified Circuit Fig.1
 Issue 9/82 TM 78994 Page 6

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 TM 78994 Page 7
Issue 9/82
 GEC Industrial Controls Limited
elk Technical Manual 78978
FV223 BI DIODE FAILURE DETECTOR
Issue 9/ 83 TM 78978 Contents Page 1.

FV223 B.I. Diode Failure Detector

Contents

SECTION 1 INTRODUCTION

1.1 Construction and Mounting

1.2 Ratings

SECTION 2 DESCRIPTION. OF OPERATION

2.1 Input Signal Level Stabilising Circuit

2.2 A.C. Amplifier
2.3 Voltage Level Detectors
2.4 Power Supply
2.5 Test Facility

SECTION 3 INSTALLATION

SECTION 4 INITIAL ADJUSTMENTS & COMMISSIONING

4.1 Operational Check

SECTION 5 TESTING & FAULT FINDING

SECTION 6 COMPONENTS LIST AND RECOMMENDED SPARES

SECTION 7 DRAWINGS AND GRAPHS.

 Issue 9 /81 TM 78978 Section 1 . Page 1.

TYPE FV223 FORM B1 DIODE FAILURE DETECTOR

1. INTRODUCTION

The FV223 is an electronic unit designed to detect the failure of a shaft mounted
diode in a brushless generator or motor. Although such failures are very
infrequent in modern machines , the use of a protective relay ensures that the
consequences of a failure are minimal and possible damage to the machine prevented.
The FV223 - B is able to differeritiate between open circuit and short circuit diodes
and this facility enables the applications engineer to achieve an optimum system
in which proper protection for the machine is provided by initiating a trip in the
event of a short circuit diode whilst retaining maximum security of supply by only
bringing up an alarm in the less severe case of an open circuit diode.

The unit operates by monitoring the voltage across a resistor in series with the
exciter field . The frequency and magnitude of the ripple changes quite distinctively
if a rotating diode fails , and the FV223 analyses this change to determine the
nature of this failure . The output signals are in the form of volt-free contacts
for use in external alarm and trip circuits . Built-in time delays ensure that
the unit does not give spurious, output signals during transients on the machine.

An open circuit diode necessitates an increase in exciter field current to

maintain the generator voltage but the increase is only a small one which is
generally well within the capability of a modern AVR. The machine can continue
to run quite normally although the response to load changes would be impaired and
short circuit boost, if fitted , would probably not operate correctly. Neither the
machine nor the system is at any immediate risk, so the signal given by the FV223
need only be used to raise an alarm . The machine can then be taken out of service
at the first opportune moment.

A short circuit shaft diode is a much more severe fault condition which requires a
very large increase in exciter field current if the generator voltage is to be
maintained . The AVR and / or exciter could be damaged if this condition is allowed
to persist so the signal given by the FV223 should be used to trip the machine and
shut it down.

NOTE:- In describing the effects of an open circuit and a short circuit diode, it
has been assumed that there is only one device in each arm of the rotating
bridge. For machines which have several diodes in series /parallel in each
arm the FV223 will only indicate correctly if a complete bridge arm is
open circuit or short circuit . Also, where fuses are fitted in series
with the diodes and these rupture in the event of a diode becoming short
circuited , the FV223 will give an open circuit indication since this is
what the bridge arm will be.

1.1 Construction and Mounting

All the circuitry is contained on a single printed circuit board which is mounted
on a sheet steel base and protected by a cover. The unit is suitable for vertical
mounting inside a control cubicle or switchboard . Overall dimensions etc., are
given on outline drawing RE4 /K5063.
 Issue 9/83 TM 78978 Section 1. Page 2.

1.2 Ratings

Input Voltage Min. 0.25V. d.c. Max. l.5V. d.c.

(across a resistor in series with the exciter field)

The unit will withstand up to 3.OV. d.c. during transient overload conditions on
the machine.

Exciter Frequency Min. 20 Hz. Max. 220 Hz.

Power Supply 20 to 32V. d.c.

(for higher supply voltages an external voltage dropper resistor is required).

Consumption lOW. at 24V. d.c. 24W. at 32V. d.c.

Output Contacts

0/C Diode .... ... 1 C/0, rated 5A. (non inductive) 250V. 50/60 Hz.
3A. (non inductive) 30V. d.c.

S/C Diode ....... 1 C/O, rated as above.

Time Delay (non-adjustable).

0/C Diode ....... 25 seconds approx.

S/C Diode .. ..... 5 seconds approx.

Maximum Operating Temperature - 550C.

r
 Section 2, Page 1
Issued 2/82 TM78978

2. DESCRIPTION OF OPERATION.

Figure 1 is a line diagram showing various functions in the FV223 and RE4/K5326
shows typical external connections.

2.1. Input signal level Stabilising Circuit.

The FV223 monitors the voltage across a resistor in series with the exciter field.
This voltage consists of a d.c. level with superimposed a.c. ripple on it, as shown
in figure 2. Both the d.c. and the ripple vary as the excitation changes with
changing load on the machine. To eliminate this effect an input signal level
stabilising circuit is used in which a field effect transistor is used as a voltage
controlled resistor.

The characteristic is shown in figure 3. This circuit reproduces the input signal
at a constant d.c. level so that as long as the proportion of ripple to d.c. remains
i constant in the input signal, the stabilisation circuit gives a constant output -
i.e., once the signal has been stabilised the magnitude of the ripple remains constant
as long as all diodes remain healthy. A change only occurs if a diode becomes faulty
and the magnitude of ripple which occurs.at fundamental frequency indicates whether
the diode is open or short circuited

2.2. A.C. Amplifier.

The d.c. output from the stabilising circuit is blocked while the ripple is passed
through an a.c. amplifier with a band pass characteristic which gives much greater
amplification of the exciter fundamental frequency than of the 6th. harmonic. The
characteristic is shown in figure 4. Exciter frequencies from 25 to 220 Hz. are
covered in three ranges, the appropriate one being selected by switch S1.

2.3. Voltage Level Detectors.

The positive part of the amplified ripple charges a capacitor producing a voltage
across the capacitor which is a measure of the peak ripple at the input to the a.c.
amplifier and also of the frequency of that ripple. The ripple at 6th. harmonic
frequency, in addition.to being less than that caused at fundamental frequency by a
faulty diode, is also amplified less, so the d.c. voltage across the. capacitor is
very small when all diodes are healthy. However, a faulty diode will result in a
definate positive voltage across the capacitor, this being considerably greater for
a short circuit diode than for an open circuit diode. The capacitor voltage is
compared with preset references in separate open circuit and short circuit voltage
detectors which operate through time delay circuits to pick up relays. The time
delays are necessary to prevent the unit giving spurious signals during transients
on the machine. A short circuit diode requires swift action so the time delay is
kept short - approximately 5 seconds - but an pen circuit diode being less serious
is given a time delay of approximately 25 seconds.
 Issue 9/81 TM 78978 Section 2. Page 2.

rl
2.4 Power Supply

The unit is designed to operate from the d.c. supply which would normally be
available for tripping and control purposes. A d.c. supply between 20V. and 32V.
can be applied directly to the unit but higher voltages require an externally
mounted dropper resistor. If a d.c. source is not available the supply may be
obtained from a reliable a.c. source via a small transformer/rectifier unit.
This situation is most likely to occur in applications involving brushless
synchronous motors as the a.c. supply is guaranteed to be present when the motor
is running.

It is essential for the safety of other equipment using the d.c. supply that there
is complete isolation between it and the input to the detector which could be tied
back to a large a.c. voltage through the voltage regulator. This isolation is
provided in the detector by a small d.c./d.c. convertor which obtains a 12V. input
from the d.c. supply and gives a stabilised 15-0-15V. output for the amplifiers
etc., in the control circuits.

2.5 Test Facility

The test facility enables the functioning of the amplifiers and relays to be
checked at any time while the unit is in service, without initiating any external
alarms or trips. The test switch and LED's which indicate that the relays have
operated are situated on the front of the unit. On closing test switch S2, which
is spring returned to the off position, the relay indicating a short circuit diode
picks up after 3 to 5 seconds, and that indicating an open circuit diode picks up
after 25 to 30 seconds. On releasing switch S2 the circuit quickly resets. .
Issue 9 /81 TM 78978 Section 3 . Page 1.

3. INSTALLATION

NOTE - This equipment should be mounted in a protected area restricted to

competent authorised personnel.

Mounting

a) The unit should be mounted in a well ventilated position not'close to or

above hot equipment . Cubicle design should ensure that the temperature of
the air surrounding the unit is not more than 10°C higher than the air
temperature outside the cubicle.

b) The unit should be moun t ed in a reasonably accessible position as there are

preset controls which may require adjustment during commissioning. In
addition , the test switch and LED indicators on the front of the unit should
be accessible for routine testing of the unit.
Issue 3/84 TM 78978 Section 4, Page 1.

4. INITIAL ADJUSTMENTS & COMMISSIONING.

The unit has been set up in the factory to detect the levels of ripple
produced by an open circuit and a short circuit diode in a normal machine.
However, it may be necessary to adjust some of the internal potentiometers to
obtain satisfactory operation of the unit. Only the following checks are
normally necessary:-

a) Check that the unit is connected in accordance with the external

connection diagram.

b) Set S1 to suit the exciter frequency . The switches are closed in the 'up'
position and open in the 'down' position.

For an exciter frequency of 25- 50 Hz., close S1/i only.

For an exciter frequency of 51-100 Hz ., close S1 / 2 only.
For an exciter frequency of 101-220 Hz., close S1/3 only.

c) Switch on the d.c. supply and check that the voltage at terminals 3 and 4
is between 32V. and 20V . These are absolute maximum and minimum values,
outside which the voltage must not deviate irrespective of loading or
boost charging . For voltages in excess of 32V. an external dropper
resistor is fitted . If necessary , adjust the value of this resistor to
ensure that the limits are not exceeded.

d) Hold the test switch S2 closed and check that D13 lights up after 3 to 5
seconds and D11 lights up after 25 to 30 seconds . Check that the supply
to terminals 3 and 4 remains within limits.

e) Run the machine on no load at rated voltage . Check that the voltage
across terminals 2 and 1 is of the correct polarity ( 2 +ve) and is more
than 250sV , but noting that at full load the voltage should not exceed
1.5V d.c. Adjust the resistor in series with the field if necessary.

4.1 Operational Check

Should it be necessary to prove the operation of the unit under fault

conditions , the machine should be run on no load with a diode disconnected
(ensure that the machine is mechanically safe to run with a disconnected
diode ). Twentyfive to thirty seconds after switching on the supply to
terminals 3 and 4, relay RL3 should pick up and give indication of an open
circuit diode . A short circuit diode is a dangerous condition to simulate and
it' is not recommended that this be done unless absolutely necessary , and only
then with the full agreement of the machine manufacturer.
Issue 9183 TM 78978 Section 5. Page 1.

5. TESTING & FAULT FINDING

The following tests are included to enable one to determine whether a unit is
faulty or not. Should a unit be faulty, it is recommended that a replacement
unit be fitted as individual components are not easily replaced except by
people skilled in PCB work and having the correct tools.

1. With the d.c. supply to terminals 3 and 4 switched on, operate the test
switch and check that relays RL5, RL6 and RL7 pick up immediately, followed
by RL4 after 3-5 seconds and RL3 after 25-30 seconds. If they do not,
check the following voltages:-

TEST POINT VOLTAGE

Across D15 12V. + 10%

TP11 - TP12 15V. + 5%
TP12 - TP13 15v. + 5%

S2 OPEN S2 CLOSED

TP3 - TP12 0 +7V.

TP4 - TP12 -0.5V. +6.5V.
TP5 - TP12 0 +1.5V.
TP8 - TP12 0 +1.5V.
TP6 - TP12 +0.8V. Ramps to -10.5V. in 25-30 seconds
TP9 - TP12 +0.8V. Ramps to -10.5V. in 3-5 seconds
TP7 - TP12 -12V. +14V. when TP6 more -ve than -10.5V.
TP1O - TP12 -12V. +14V. when TP9 more -ve than -10.5V.

2. With the supply to terminals 3 and 4 switched on, run the machine and check
that the d.c. voltage between terminals 2 and 1 is above 25OmV. with the
machine on no load, and below 1.5V with the machine on full load. Check also
that the d.c. voltage between TP1 and TP12 is between 40mV, and 60mV. and
follows the characteristic shown in figure 3 as the excitation is varied.
If the characteristic is not as shown the field effect transistor TR1 is
probably faulty. The characteristic shown in figure 3 may also be checked
using a separate variable 0-2V. d.c. supply.

3. Using an oscilloscope, check that the peak-to-peak a.c. output from ICI/2
(TP3-TP12) remains approximately constant as the excitation changes from no
load to full load.

On some machines with an abnormally high` residual voltage it may be found

that the voltage at TP3 reduces noticeably as the excitation increases.
If this is the case, adjust RV1 to make the voltage at TP3 remain approximately
constant from no load to full load.
 Issue 9/83 TM 78978 Sections 5,6 & 7.

4. Run the machine with an open circuit diode and check the voltage at TP3-TP12
with an oscilloscope. Potentiometer RV3 has been set in the factory to detect
a positive peak of 1.6V. or greater. If an open circuit diode results in a
positive peak of less than 1.6V., reduce the setting of RV3 until TR2 switches
on (monitor TP5-TP12). Reducing the setting of RV3 too much may make the unit
sensitive to the normal AVR ripple if the frequency of this is close to the
exciter frequency, so do not set RV3 lower than is necessary.

Potentiometer RV4 has been set in the factory to detect a positive peak of
4.5V. at TP3. In the unlikely event of an open circuit diode resulting in a
voltage large enough to give a short circuit indication, increase the setting
of RV4 until TR3 turns off (monitor TP8-TP12). Increasing the setting of RV4
too much may result in the unit not detecting a short circuit diode, so do not
set RV4 higher than is necessary.

5. Insulation Resistance - disconnect the unit. Link all terminals together

except the earth terminal, and check the insulation resistance to the chassis
with a 1000 volt megger. It should be greater than 20 megohms.

6. COMPONENTS LIST AND RECOMMENDED SPARES

All components are mounted on a single printed circuit board reference:-

650 - 23X2175 - PlO.

It is recommended that a complete unit to reference REP/K5043/Al be held as a

spare.

7. DRAWINGS & GRAPHS

Line Diagram of FV223-Bl Fig. 1

Typical exciter field current waveforms Fig.2

Input stabilising circuit characteristic Fig. 3

A.C. amplifier characteristic Fig.4

YIN GP6 Resistor Unit Outline RE4/K5512

Typical external connections RE4/5326

FV223-B1 Outline RE4/K5063

 F- Section 7.
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Issue 9/83 TM 78978 Section 7, Page 5.

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1, T-111i

MOUNTING BAR

MOUNTING BARS TAPPINGS AND CONNECTION NUTS

ARE NOT INCLUDED IN THE BASIC UNIT. THESE ARE TO SE
PICKED UP ON THE ECUIPMENr USING THE UNITS
REFER TO X24710.98

NOTES i) THE GPG REF. No, IS MOUNTED ON A TAG DESLDE

.....THE .END TERMINALS

2) THE SHUNT RESISTOR I5 NORMALLY ABouT 5 OHMS OR

LESS AND HAS A G REF NO OF 8 OR LE55

3) THE SUPPLY RESISTOR (IF REQUIRED ) IS NORMALLY

ABOUT 50 OHMS OR GREATER AND HAS A GP6 1SEF
N°• OF as OR MORE

DRAWN C T P•.-..,ca GEC INDUSTRIAL CONTROLS LTD.,

DATE 27LIO 82 RUGBY, ENGLAND
DEPT. PCPOO
PTS T OUTLINE OF
Issue 9/83

RE4/,rS326

TYPICAL EXTERNAL CONNECTIONS,

r-------- -i
$ FV223-B _
' DIODE FAILURE
DETECTOR

EXTERNAL l I - 5

[ F TO
= p1 6^ OPEN CIRCUIT DIODE
ALARM CIRCUIT

7I
EXCITER (
FIELD ( I
V
A. %'.
EXCITER
8)

TO
91 SHORT CIRCUIT DIODE
TRIP CIRCUIT.

I t
Id
+

DROPPER I
RESISTOR
D.C. (REQ'D FOR 4
SUPPLY SUPPLY VOLTS I I
20-146V.. GREATER THAN I
32 VOLTS) I '
14 ^

I
OR r f;I/°,nerw,venr. GEC INDUSTRIAL CONTROLS LTD.
RUGBY, ENGLAND
P r P n n
 Section 7, Page 8.^.
Issue 9/83 TM 78978

DIMENSIONS IN MILLIMETRES REV K5063

FIXING HOLES 7 DIA.

C

WEIGHT - 2 KG.

DRAWN GEC LNOUSTREAL CONTROLS LTD.,

DATE_
j
RUGBY. ENGLAND
!AEP7 PCPOO DI ODE
OUTLINE OF +^.
F 11 a iS TG C.. . ntgrtr CAllef-dl
 GEC Industrial Controls Limited ri
F*A Technical Manual 78977
CHECK SYNCHRONISING UNIT
TYPE FYC 42

elk
 Issue 1 /81 TM 78977 Contents Page 1.

CHECK SYNCHRONISING UNIT TYPE FYC42

LIST OF CONTENTS

1. LIST OF DRAWINGS.

2. INTRODUCTION.

3. SPECIFICATIONS.
3.1 Supply Voltages.
3.2 Synchronising Settings.
3.3 Voltage Matching Error.
3.4 Unbalanced V.T. Correction.
3.5 Contact Rating.
3.6 Flash Test Capability.
3.7 Operating Temperature Range.

4. TECHNICAL DESCRIPTION.
4.1 Phase and Slip Error Detector.
4.2 Voltage Matching Error Detector.
4.3 Safety and Protection.
4.4 Internal d.c. supplies.

5. INITIAL ADJUSTMENTS & COMMISSIONING.

5.1 Safety Pre-check.
5.2 Synchronising Phase / Slip Settings.
5.3 Voltage Matching Selector.
5.4 V.T. Unbalance Compensation.

6. TESTING & FAULT FINDING.

6.1 General.
6.2 Internal Supply Voltages.
6.3 Voltage Unbalance Check.

7. COMPONENTS LISTS & RECOMMENDED SPARES.

7.1 Spares Recommendations.
f' 7.2 List of Components.
Issue 1/81 TM 78977 Page 1.

CHECK SYNCHRONISING UNIT TYPE FYC42

1. DRAWINGS

Circuit Diagram of.FYC42 - 650-23X-2169-F03.

External Connection Diagram - RE4 / K5087.

2. INTRODUCTION

The FYC42 Check Synchronising Unit is intended for use in manual generator
synchronising schemes to ensure accurate synchronising by eliminating possible
operator error. The output relay contacts will become closed only while the
incoming generator is within the permitted synchronising bandwidth and
pre-selected tolerances.

Internal switches are provided to select the maximum permissable errors for slip
frequency , phase, and voltage mismatch . See Section 3 for details of available
settings.

3. SPECIFICATIONS

3.1 Supply Voltages

110 Volts or 415 Volts , + 20%, 50 / 60 Hz., single phase.

Running Supply burden - 10VA at nominal volts.

15VA at nominal . + 20% volts.

Incoming Supply burden - 2.5VA at nominal volts.

5VA at nominal + 20% volts.

3.2 Synchronising Settings ( Slip and Phase Error)

There are three switchable options:-

SLOW: 0.07 Hz . max. slip with + 10° max. phase error.

NORMAL: 0.12 Hz. max. slip with + 10° max . phase error.

FAST: 0.20 Hz . max. slip with + 20 0 max. phase error.

Back-up phase detector + 30° overall settings.

3 3 Voltage Matching Error

There are three switchable options:- +2%, +5%, +10%.

Breaker closure is inhibited when voltage mismatch is outside these limits.

3.4 Unbalanced V.T. Correction

A potentiometer adjustment permits correction of the voltage matching detector to

compensate for small differences in the V.T. secondary voltages , if required.
 Issue 1 /81 TM 78977 Page 2.

3.5 Contact Ratings

Both output contacts are rated at:-

5 Amps at 250V. a.c.

2 Amps at 440V. a.c.
1 Amp at 110V. d.c. (inductive time constant less than 40m/secs).

3.6 Flash Test Capability

2kV. a.c. between inputs, input/output terminals, and to earth.

3.7 Operating Temperature Range

Minus 10°C to plus 65°C.

4. TECHNICAL DESCRIPTION

Refer to the circuit diagram - Drawing No.650-23X-2169-FO3.

4.1 Phase and Slip Error Detector

The 20 volt secondary windings on each of the running and incoming supply
transformers (Tl and T2) are connected together in series opposition. When the
voltage, phase, and frequency of the two supplies are exactly equal, the combined
voltages (i.e. between TP3 and TP4) will be zero. Any error will produce an a.c.
voltage which will be rectified by D7-D10 and fed into the amplifier switch
IC1-C via the input resistor R13. Resistors R10, R11 and R12 provide bias
currents to permit phase errors of up to 10° or 20° as selected by the Sync.
Selector switches Sl/1/2/3. This part of the circuit is very insensitive to
input voltage errors.

The phase error voltage at the output of diode bridge D7-DlO will charge up
capacitor C4. If the slip error (i.e. the difference frequency) is high then C4
will not have time to discharge between the slip cycles, therefore keeping the.
error voltage continuously high and preventing the amplifier from switching. The
discharge time constant of C4 will determine the maximum permissible slip, and the
/'. discharge resistors R7, R8 and R9 are also selected by the switches 51/1/2/3 to
give maximum slip frequencies of 0.07, 0.12 and 0.2 Hertz.

The output of the amplifier/switch IC1-C switches the transistor TR1 which
energises the output relay RL1.

The amplifier/switch IC1-B and R20, R21 act as a back-up phase detector switching
at 30°. When the phase error exceeds 30°, transistor TR1 is biassed hard off by
the amplifier ICI-B and will not respond to a switch-on signal from the main
amplifier ICI-C.

4.2 Voltage Matching Error Detector ^a•<:

Rectified voltages from the running and incoming supply transformers are subtracted
at the junction of resistors R28/R29 and any difference voltage fed as an error
into the amplifier ICI-D. When the amplified error exceeds approximately 7 volts,
the zener diode D.31 conducts, sending a bias signal to hold off the main
control/amplifier switch IC1-C.
 Issue 1 /81 TM78977 Page 3.

Resistors R32, R33, R34 set the gain of IC1-D and are selected by the Voltage
Matching switches 52/1/2 / 3 to provide maximum permissible voltage errors of 2%,
5%, and 10%.

The amplifier IC1-A is a unity - gain inverting amplifier which reverses the
polarity of the negative errors so that these become positive at the output of
diode D26 feeding the zener diode D31.

The voltage matching circuit becomes inhibited immediately the main control
amplifier energises the relay via the feedback circuits R40/D22 and R37/D25.

4.3 Safety and Protection Circuits

If the minus 12 volt internal stabilised d.c. power rail fails or becomes low, then
the inhibit transistor TR2 will conduct via its input biasing resistors R25 and R26.
TR2 will short the input drive to the relay switching transistor TR1 and prevent
energisation.

The charging current of capacitor C3 will also cause TR2 to conduct during the
initial build - up period only when the supplies are first switched on.

The voltage transient surge suppressor SDI fitted across relay and switching
transistor protects the transistor against abnormal input transient spikes.

Control circuits associated with the selector switches , balance setting, and
calibration potentiometers are all "fail - safe": i.e. - an open-circuit in any of
these would tend to prevent the output relay from energising.

4.4 Internal d.c. Supplies

Zener diodes D29, D30, and smoothing capacitors Cl and C2 provide stabilised +12
and -12 volt supplies to the IC amplifiers and control circuits.

The rectified output from diodes Dl and D2 provide an unregulated , unsmoothed, d.c.
supply of approximately 24 volts for the output relay.

5. INITIAL ADJUSTMENTS & COMMISSIONING

NOTE:- The unit is despatched from the Works with the Synchronising Setting
selector switched to 'NORMAL ' position, and the Voltage Matching selector
switched to + 5% position . These settings will suit the majority of
applications for small and medium sized generator sets on independent
busbar systems.

5.1 Safety Pre-check

Before attempting to close the circuit breaker it is advisable to check that the
two supply voltages to the unit are correctly phased. Check by the normal phasing
I out methods across the generator circuit breaker that the synchroniser relay
contact only closed when the generator is in-phase.

5.2 Synchronising Phase / Slip Settings

Internal ' SYNC.SETTING ' selector switches ( S1) provide three fixed combinations of
phase and slip frequency errors for synchronising:-
Issue 12/83 TM 78977 Page 4.

1. SLOW - Phase error + 100 max.

Slip 0.07 Hz. (i.e . 1 cycle in 14 seconds) max.

2. NORMAL - Phase error + 100 max.

Slip 0.12 Hz. (i.e. 1 cycle in 8.3 seconds) max.

3. FAST - Phase error + 20° max.

Slip 0.2 Hz . (i.e. 1 cycle in 5 seconds) max.

Remove cover of unit for access to the selector switches. Only one of the
three adjacent switches ( 51/1/2 / 3) must be pushed forward to the ON position.

5.3 Voltage Matching Selector

Internal VOLTS MATCHING selector switches (S2) provide three fixed settings
for maximum allowable voltage mismatch . Only one of the three adjacent
switches ( 52/1/2 / 3) must be pushed forward to the ON position.

1. +2%. 2. +5% . 3. +10%.

For generators paralleling onto main feeders or infinite bus systems , the + 2%
volts match setting is recommended . For systems which are not infinite bus
the + 2% or + 5% setting may be used.

5.4 Voltage Transformer Unbalance Compensation

If it is suspected that the running and incoming V.T's have unequal secondary
voltages due to unequal loading, regulation , etc., then the voltage matching
detector may inhibit or restrict operation , especially when using the + 2%
setting . Before adjusting the compensator , unsolder one end of the test link,
situated in the top right hand corner of the printed circuit board ( pcb) and
isolate . Adjust the incoming generator bus voltage to be exactly equal to the
running busbars ( preferably using the same voltmeter to eliminate meter
errors). Now adjust the volts balance ( RV2) potentiometer screw ( adjacent to
switch S2 ) to give zero volts d . c. between the two test lugs marked TP1 and
TP2 (just above the IC amplifier).

NOTE :- After adjustment of RV2 , resolder the test link which should connect
across the lugs marked A and B.

Finally refit the cover and ensure the star - washers are fitted beneath the
cover to ensure adequate earthing of the cover.
Issue 12 /83 TM 78977 Page 5.

6. TESTING & FAULT FINDING

6.1 General

If the unit is suspected of being faulty , first check the two input supplies
at the terminal block . The output relay has a clear protective cover and its
contacts can be seen to operate when the supplies are in - phase if the unit is
functioning correctly.

It may be convenient to prove the relay will operate by carrying out the
following test:-

Disconnect the wires at the unit terminal block for the incoming supply
(terminals 1,2, or 3) and the closing contact ( terminals 7 & 8). Now
,temporarily parallel the inputs at the terminal block ( e.g. link 1 to 4, 2 to
5, for 11OV inputs ). With the running supply energised the relay contact
should now close and remain closed : otherwise the unit is faulty.

6.2 Internal Supply Voltages

NOTE - Unit printed circuit boards and components are protected by a coat of
clear polyurethane varnish. When checking voltages ensure that
either sharp - pointed test meter prods are used or that the varnish
is scraped off when connecting the test meter.

(i) The internal stabilised +12V d.c . supply can be measured across
either zener- diode D30 or electrolytic capacitor C2.
(12V + 1V tolerance)
c. supply can be measured across
(ii) The internal stabilised - 12V d .
either zener-diode D29 or electrolytic capacitor Cl.
(12V + 1V tolerance)

(iii) The relay unregulated d.c. supply can be measured across the surge
suppressor SDI (just above the relay ). With the relay not energised
this voltage should be between 21 and 32V d.c.

6.3 Voltage Unbalanced Check

To ensure that the relay closing is not being inhibited by the input supply
T. unbalance compensator adjustment as
voltages being unbalanced , check the V .
given in Section 5.4.

`7. COMPONENT LIST & RECOMMENDED SPARES

7.1 Spares Recommendations

A relay is the only item normally recommended as a spare . Alternatively a

complete spare unit can be supplied where this is considered to be necessary.
 Issue 1/81 TM 78977 Page 6.

1 7.2 LIST OF COMPONENTS

REFERENCE VALUE TYPE ORDERING REF.

Resistors:-

R1,R2 330 ohms. 60402/291

R3 39 ohms. .60202/224
R4 100 " " 254
- R5,R6 2.2k ohms If 350
R7,R13,R32 220 ohms. 494
R8 82 " 464
R9 120 476
R10 390 512
R11 39 " 440
R12 150 482
R14 3.3 " 362
R15,R16 100 " 470
R17,R38,R25 1.5 " 338
T R18,R22 1 326
R19 33 " 434
R20,R34 1 M ohm. 542
R21 560 k ohm. 524
R23 10 398
R30 22 422
„ „
R31 15 410
R27 10 " 182
11 1, „ 11 O
828,29,39,24 47 " 374
R33 470 518
11 " ❑ 1, 1,
R35,36 47 •" 446
R37 18 416
R40 68 458
„ 1, ,1 11 ,t
R26 1.2 " 332

Capacitors•-

470 pF 25V. -10+50%. Al. Electrolytic. 69059/308

220 pF 16V. -10+50%. it. 69045/300
10 pF iOOV. +20%. Plastic Film. 67085/268
lnF 100V. +20%. Ceramic. 66601/172
470pF 100V. +20%. Ceramic. 66601/164
2.2pF 10OV. +20%. Plastic Film. 67079/252
470nF 100V. +20%. Plastic Film. 67079/236
Y
Int. Circuits:-

IC1 Quad. Op. Amp. NAT.SEMI. type LM348N. B.O.C.

Diodes:-

D1 to D10 600V. IN 4005. 71545/370

Dll to D13 200V. IS. 923. 71078/350
D14 to D28 75V. IN 4148 71262/240
D29,30 12V. Zener BZY95 C12. 72240/470
D31 6.2V. Zener BZY88 C6V2. 72080/320

eN
 TM 78977 Page 7.
Issue 1/81

TYPE ORDERING REF.

REFERENCE VALUE

Potentiometers:-
64390/305
RV 1 200 ohms. 3255W.
3255W. 64 390/329
RV 2 500 ohms.
64390 /401
RV3 10 k ohms. 3255W.

Relays: -
GPR101/350/4C/S/X/F/V/D/R/N. 86110/253
RL1 24V.d.c.
86110/ 90 1
Plug Base & Clip for RL1.

Transistors:-

Mullard BSW67. 75411/250

TR1 75240/100
TR2
BC107B.

Transformers:-

Parmeko 77819 RE4/T97528/1

T1,T2

Suppressor:-

P6KE82C. 71955/621
SD1 66V.

Switches:-

3 pole, 2 position type SDD3 (Erg) B.O.C.

S1,S2
 fRE4/K5087

INCOMING VOLTAGE L1 '

(GENERATOR)
110V OR 415V ±20% 210V__ 2 CHECK
2.5VA AT NOM. VOLTS ^_^ SYNCHRONISING
5VA AT NOM. +2O/ 380/450V UNIT
3 TYPE FYC 42

RUNNING VOLTAGE L1
(COMMON BUS)
110V OR 415V ±20% 110V _ 5
.10VA AT NOM. VOLTS
15VA AT NOM.+2O% L2-C
`_ 380/450V 6

TO CIRCUIT-BREAKER
CLOSING CIRCUIT to --O 0--i
1 1
9^1
TO SYNC LAMP OR 1
NO-VOLT COIL CIRCUIT 10

STUD

TERMINALS CONTACT RATINGS

MAX WIRE SIZE 5A AT 250V A.C.
2.5mm2 2A AT 440V A.C.
(eg 7/0.67) 1A AT 110V D.C. (IND. T.C. LESS THAN 40 M.SEC.)

TITLE
CHECK SYNCHRONISER FYC 42
EXTERNAL CONNECTION DIAGRAM
PRAWN GEC INDUSTRIAL CONTROLS LTD.,
DATE 21-11-80 RUGBY, ENGLAND.
DRG. No.
!:-LANK ,II' f 011111
UNAWING Ni,

GEC - Industrial Controls Ltd

{ RUGBY
650 23X 2169 F63'
ENGLAND
SHEET No OF SHEET

CIRCUIT DIAGRAM
CHECK SYNCHRONISER FYC42

1
P
ROCIFESTER INSTRUMENT SYSTEMS, LT I)

SERIES -I'M 246()

TEMPERATURE MONIlOI2
INSTRUCTION MANUAL

I I.1 ; tsci
 CONTENTS

PAGE NO.
DESCRIPTION

Project Summary 3
1.0
Data Bulletin
2.0
System Description 8
3.0
Installation Instructions 15
4.0
Operating Instructions 17
5.0
System Calibration 18
6.0
7.0 Trouble Shooting 22

8.0 Recommended Spares 24

9.0 Manual Drawing Index 25

C A U T I O N
HEALTH & SAFETY AT WORK

INSTRUMENTS CONTAINED IN THIS MANUAL CAN HAVE MAINS VOLTAGE AND IT IS

EXTREMELY IMPORTANT THAT THE INSTRUCTIONS CONTAINED HEREIN ARE STRICTLY
ADHERED TO.

We also recommend the following:-

1. Only entrust the work to properly trained personnel.

2. Cross check the data plate with this instruction Sanual to
ensure that the correct documentation is being used.
3. Study the instruction manual and any warning notices on the
instrument.
4. Check by visual inspection whether the instrument is connected
to an electrical supply . If it is , take appropriate precautions
ri to ensure a safe condition and at all times avoid accidental
contact.
5. Check by visual inspection whether the instrument is connected
to the process . If it is , take appropriate precautions to
ensure a safe condition.
6. Unauthorized modification or repair of instruments may
invalidate warranty . We strongly recommend that they are
returned to the manufacturer.
 Sheet No. i
1.0 PROJECT SUMMARY

CUSTOMER (END USER)

PURCHASER
RiS CONTRACT
PURCHASE ORDER _

ITEM

QTY Temperature Monitors ( each ) equipped with

Triple detector Modules and ranged as follows:-

a) Detector Modules

OUTPUT I TRIP I RELAY

CHANNEL DETECTOR SENSOR INPUT
TYPE RANGE RANGE MODE STATUS
NOtS. MODULE TYPE

1,2,3,
4,5,6,
7,8,9,
10,
13,14,15,
16,17,18,
19,20,21,
22,23,24,
25,26,27,
28,29,30

TYPE NO
b) Meter/ Common Service Module

SENSOR TYPE RANGE

1.

2.

c) System Power

d) Special Features

TM2480
OCT 79
PAGE 3
3.0 SYSTEM DESCRIPTIONS
de to continuously
The Series TM2480 isusing RTDdresistance and/or monitor
thermocouple
remote
temperature points using
. "Alarm" and "Shutdown" functions are provi©edeattura
sensors
indopondant preset temperature levels. Each point
"Shutdown" an
with its associated "Alarm"
dis splay
be ssloctod and di
within the system enclosure. Voltage free contacts are
provided by an optional per point relay which
totriho atwrdisplayt
and can be used to drivo an annunciator or lamp unit.

In addition analogue output signals are available per point

for customer use, as a computer interface or to drive exttrnal
recorders/indicators. Local L.E.D. indication of pointTrip
is also provided as are Group Alarm/Roflash and Group
relays for use as common system functions.

The series TM2480 consists of two panel mounting systems,

TM2481 (6 points), TM2482 (12 points) and one rack-mounting
systom TM2485 (up to 30 points). For larger systems,
additional TM2485's are used, expandable in increments of
3 points. In any systom whore the total number of detector
module locations are not used, "blank" panel(s) can be fitted
as required.
All modulus in the systems a=o standardised plug-in typo and
are removable from the front. Field wiring connections arc
made at the roar of the enclosures via scrow-typo barrier
terminals (TM2481/2) and high-donsity clamp - typo terminals
(TM2485). System power is 117/240V AC 50/60Hz, as standard
or 24V OC non-isolated as an option.

TM2481 Panel Mountinqjnclosuro TYPa 25 0432

3.2
The Tf2481 system has the capability to monitor up to six
panel-
individual temperature points. It is housed inn0one ,
enclosure 8.2" (20Bmm) wide, 10.6" ( ) high,
mounting
12.511 (318mm) deep (including bezel). The enclosure can
accept two triple-input RTD or Thermocouple Detector Modules
plus the system Motor/Common Service Modulo. The location
and ranging of the detector modules are defined by
order to suit the particular requirements of the
customer
system installation.
-typo terminal blocks used for field wiring are
The scrow
into the following groups of connections:-
segregated

1. SENSOR INPUTS
SET NO. 1
2. PER POINT RELAY CONTACT
3. ANALOGUE OUTPUTS
SET NO. 2
4. PER POINT RELAY CONTACT
5. GROUP RELAY CONTACT SETS
6. MAINS POL;ER INPUTS

TM2480
OCT 79
PAGE B
 o grogato
aplows itnt s
Th i s ar r a n gement separatecfunctions
sots available on par p oint
as follows:-
Contact Sot No. 1 for control action,
Contact Sot No. 2 for indication or computer input.

For furthor details on TM2481 systom wiring refer to manual

drawing index in section 9 for customer connection diagram.

Enclosure T o 2504-328
3.3 TM2482 Panel Mountin '
The TM2482 system has the capability to monitor up to twelve
It is housed in one panel
individual temperature points .
mounting enclosure 10.6" (268mm ) wide, 10.6" e nclosure high
cant
including bezel). T he
12.5" (318mm ) deep (input RTD or Thermocouple Detector Modules
accept four triple - . The location
plus the system Motor/Common Service Module
and ranging of the detector modules are defined by customer
ardor to suit the particular roquiromonts of the system
installation.
typo terminal blocks are again segregated into
The screw -
convenient groups of connections in a similar way to those
of the TM2481 referred to in section 3.2.

For further details on Tf12482 system wiring refer to manual

drawing index in section 9 for customer connection diagram.

3.4 TM24B5 Rntinq Enclosure Type 2504-333

The TM2485 system has the capability to monitor individual

i ss2housed
temperatures up to a no m i nal high,
os. (2Tho' s ystom
0 int
e n closure
in a 19 11 rack mounting
The enclosure can accept up to ton triple-
(316mm) deep .
input RTD or Thermocouple Detector Modules plus the system
Servicc Modulo. The location and ranging of
Motor / Common •
detector modules are again defined by customer ardor to
suit the particular roquiromonts of the systom installation.

All field wiring connoctions to the TM2485•are made via high

typo terminal blocks. Again the connections
density clamp -
are sogrogatod into convenient groups in a similar manner
p tio n tha
as the TM2481 and TM2482 with the e xce t tathentwo
act
halves of individual channel relay con t
located in the samo connection blocks.
, additional
For systems required to monitor more than 30 points
Where application suits, one
TM2465 chassis are employed . chassis containing Common
TM24B5 is designated as the "Master " subsequent "Slave" chassis
Service Modulo and Digital Display ;
contain the desired amount of Triple Detector modules plus an
Interface Module which are connected to,
Auxiliary Power Supply /
the master chassis via 18 way cable harnesses.

TM2480
OCT 79
PAGE 9
 yp o '2504-301
Tri to Thermocou to Detector modulo T
3.5 uits for
This detector module contains the monitoring circ
(trip) functions for throe monitored
alarm and
temperature points and can be ranged to suit most typos
of thermocouples.
The input circuits are fully isolated from system internal
supplios to achieve good common and series mode rejection
ripple and noise. Each channesl has
an optional relay
with two sots of changeover contacts and circuits are provided
so that it can be initiated by either the alarm or shutdown
selectable by a simple on-board link.
(trip) functions,
In addition_to this the per channel relays can be initiated
alarm and trip functions when high-low
trip mode is used.
Also, if desired, one or two of the relays can be linked
for group alarm and/or group trip function per detector
module. Another possible variation is to arrange onto
the t
trip
modulo so that the ap secondtgroup trip for three
alarm highway thus generating alarm relay
system and the common service module's group
than becomes Group Trip 2 relay.

All those variations are again affected by simple on-board

links details of which can be found on Drawing No. 2504-301.

Per channel alarm and trip sot points are ostablishod and'
are fully adjustable to ±0.5°C over the range, by moans of
stable, modulo mounted, multiturn potentiometers (blind sot),
with outputs to the motor module for digital indication of
the sot point temporatures. Local LE.D. indication of
module. for each
alarm and shutdown
six L.E.Ws per pushbuttons per channel and point
moduleo has
module has push-to-road p
description service labels.
The circuit diagram of this modulo (C2504-301) is located
channel is
in Section 9 of this manual whore one comple efor
shown. Circuits B and C are identical except
common to the throe channels.

This module accepts the millivolt input signal frrommstheDC

thermocouple sensor which is ofpoe zi act
db ack•loop to control the
amplifier with an integrating - isolator 23
pulse-width modulator formed by Z2. The opto
-width modulated signal
driven by the pulse viaw01.
hich bTheers
pho to-h transistor h pulsed signal . Two sections of R33
and pphase- corrects the e
together with C8 and C9 form a two-section inati^g
li fier.
filter and food the signal conditioning amp
A cold-junction reference signal generated by Q2 and Z6
also foods Z7 to compensate for changes in ambient temperature.
The sensor transistor Q2 is mounted on roar terminal block
board to obtain the most accurate cold-junction tomporaturoi

TM2460
OCT 79
PAGE 10
Z7 and 43 provide an output signal which is used to perform
the following functions:-
poraturovico module for
mmon
o
a) It provides an output t
oithe co
digital indication of poi nt
b) It provides an analogue output via R45 for customer use.

c) It provides a signal to compare with the levels set by

RV3 and RV4 at comparators Z8-1 and Z8-3 which drive
alarm and shutdown circuits.

The output signal from Q3 will be 0 to 5V or 1 to 5V D.C. zero

true"
the customer has specified "
dependant upon whether
ut
or "live" zero analogue outp
and "trip" circuits comparator circuits incorporate
The "alarm " r low
comprehensive linking facilities fo dos,
energised relay o automa t ic
energised or de - t initiated by a
relay circuits with a manual group ut
Module.
pushbutton in the Common Service

The following description of circuit operation assumesnorgisod

high-high trip mode has boon specified with normally

relays:-
the output signal from Q3 is lower
Under normal conditions , .
than the voltage levels set on RU3 and RV4 Thebeasociateod
" alarm " or "t r i p "
relay whether linked for
E.D.'s will be extinguished.
and both L .
the
When the output signal from Q3 emitterrc xcooid the voltage11
the alarm circuitry will ) will de-on r9ioo•
set on RV3 , if linked for alarm
light and relay K1 (
When the output signal from Q3 exceeds the voltage 1 11 tiont
RV4, the trip circuitry will activate, will de-energise. If the
and relay K1 (if linked for trip ) wil l
comparator circuits are linked for automatic rosot If theycomp alafor
the
.
do-activate when conditions turn re to normal mp
circuits are linked for latch mode they will remain activated

until both:
a) Conditions return to normal pressed
Manual reset pushbutton is pTo at which
then b )
point the circuit (S) will do-activate.
ora te a
The comparator circuits also incorp
e signal f rom and failidetector,
e d by a neg ati v
this is acti v at will occur when the
.
the alarm cir c uit only circuit mode.
thermocouple fails in open-

TM2480
OCT 79
PAGE 11
 point readout selection is initiated by pressing pushbutton
the quad
n01 of the module. This
P61 on the front pa outputs from Z3 and
which
analogue tcPaton tiometerslRV3iand RV4 onto the motor
the sot. Point nals Thoseorwill
signals be
highway bus P2-11, P2-12 and TD
ng for PTD pressed
0-5V DC or 1-5V DC. Also coding
isrouted onto the highway when the road pushbutton is p
to select the relevant motor scaling and linoerising circuit in
the motor/common service modulo.
are generated
isolated supplies for the three input circuits rated
by oscillator Z10 and V-PETS Q8 and Q9 driving giT1 primary in
push-pull mode. Three independent secondary supplies
rectifiers food channels A, B and C. Non-isolated
are common to the three channels.

3.6 Tri l0 RTD Detector Module Type 25D4-306

The RTD Detector Module contains the monitoring circuits for

alarm and trip functions for three monitored temperature points
and can be ranged to accept inputs from Nickel orCplatinum.
RTD Sensors. Please rofor to section 9 Drg. No.

The modulo incorporates a constant-curt thre toire bridge

circuit (comprising of Z1-2 and Z1-3) connected
RTD sensor, to ensure accurate compensation of sensor load
resistance. The millivolt signal produced aspplied ducthgfinput
aa
the constant current and RTD resistance is a
of amplifier Z1-1. This amplifier produces at its output an
analogue signal of 0-5V DC or 1-5V DC in a similar fashion as
that of the Z7/Q3 combination in the Thermocouple Detector
circuit. The input circuit of the RTD detectorocircuitiis not
isolated from the system power supplies.
detection circuit for RTO detector modules will initiate the
alarm circuitry foren or short-circuit sensor failure
when linked for high/high.
operation is
o 2504-301d.
thea TripleThermocouple Detector Modul

3.7 Motor Common Service P1odulo

/Common Service
equipped with one Motor
Each TM2480 system is
Modulo which supplies power to the detector modules and provides
digital readout of channel temperaturesandssot point-state,
Selection of those readouts is made by m
interlocked, pushbutton circuits with LED's to acknowledge
parameter selected.
is automatic by moans of link facilities on
Range selection
detector modules which address and select the correct motor
circuit when channel readout pushbutton is pressed. Thesensor
one or two
accept and lineariso signals from
module (one
can RTO and/or one T/C) each with its own specified
types
range.

TM24BO
OCT 79
PAGE 12
Pushbuttons and circuits for solocting in-service motor
calibration chocks are also located in
n Uthisa odulo, plus
the common alarm /roflash and trip 1
fittod will
The typo of motor c customer when ordering the system.
od
roili bythe
and range sos manual drawing
Alternatives s are listed in the lexpla nnation refer
section 9 , but for the purpo
to Drg . No. C2504-312.
and linoarising circuits for any
This card contains scaling
from the two available in those group
one range
0 - -1200 C
2 or 3 wire 100 ohm PLAT RTD
a) _100 __ 4000C

0 2000C
Typo 'Kt Thermocouple
b) It n
-100 =j11000C

can be displayed in the equivalent

As an alternative ranges
value for 0r.
The output signals of 0-5V DC or 1-5V DC proportional to point
temporaturo, "alarm" sot point and "trip" sot point are switched
onto the motor bus highway and in turn onto the motor card via
P22-11,12,13, when the point readout pushbutton is pressed.

Pushbuttons PB1-5 on the front panel of the modulo are bsod to

select the dosirod parameter to be displayed on the digital
indicator.
Those pushbuttons are used to address the clocked counter Z10
an interlock. When a pushbutton in
acting as . presseg
corresponding output
it is not already locked in", i.e
Z10 is low, than this low is transferred to the enable input.
from
The outputs now count in order, at clock speed until the soloctod
the
now
'q' output goes high. This T s_Onab es theocounternand will
now locked high. he high
output is LED driver and the relevant analogue gate on Z11.
energise
The soloctod analogue signal from the motor highway is switched
scales
to the input of Z1A which, with its associated circuitry,
and do-biases the signal. Thermocouple signals are li orisod
with respect to temperature by quad amplifiers Z3, 4,usts
5 5 and gain
. The break point circuit adj
associated components
of Z3A at defined temporaturo/voltage levels to correct for
Range select linos gate
thermocouple non-linoaritios . to the
the desired signal from Z12 and this is than fod di
display I.C. Z14. This I.C. produces a 31 digit f
temperatures with selectable decimal points for low temperature
ranges.

TM2480
OCT 79
PAGE 13
 system "GroupA1arm//ROfan5h" a
The optional common a ndi"AWR"
relay circuits are formed by Z6, 7,8 for these relay circuits
sequence
component s. The operating
is shown in the following table:-

K6 GROUP GROUP
SYSTEM K5 LINKED FOR K5 LINKED
TRIP INDICATOR
STATUS FOR GROUP ALARM FOR AWR *LP6
/REFLASH
ENERGISED OFF
ALL POINTS I ENERGISED
NORMAL
ENERGISED

ENERGISED
DE-
ENERGISED
DE-
SUBSEQUENT 1 ENERGISE FOR ENERGISED
POINT TO # SECOND THEN
ON TRIP
ALARM OR DE-ENERGISED
ONLY
TRIP

RESET DE-ENERGISED
AUDIBLE
DE- ENERGISE,p OFF
ENERGISED

*NOTE: The audible reset pushbutton and group indicator lamp

PB6/LP6 is located on the front panel of the common service
to reset detector
module and the reset function is also used
alarm circuits if latching mode has boon specified.

The meter calibration check circuit comprises of analogue gates

, 8 pushbutton/lamp PB4/LP4, PB5/LPS and reference voltage
Z12A Z1D.' When the "Zero" and "FSD" pushbuttons are pressed,
generator
corresponding to zero and full scale ranges respectively
voltages
into the metering circuit. These voltages are
are switched
0-5U DC or 1-5U DC depending on specified analogue outputs.
potentiometers can now be adjusted in conjunction
Zero and span
with the depression of a readout pushbutton on a detector module
and full scale indication of the range of the point.
to give zero
. This feature can therefore be used to chock and
selected
the meter "SPAN" and "ZERO" potentiometers without
re-calibrate
taking the system out of service.

TM2400
OCT 79
PAGE 14
3.8 Power Supplies TM2480
TM2481 and TM2482 have an identical power supply. It consists
of transformer TX1, bridge rectifier and smoothing ecapacitsories
plate
C20 located on the Common Service Module back
of voltage regulators and associated mpoocatedoonotheg
Common Service Module Card. The supply generates
voltages to power the system:-

a) +24U unstabilised for relay supply

b) +12V stabilised for meter card and triple
detector modules.
c) +5.7V to power the digital motor.
d) -12V for meter card and triple detector modules.

The components on the module backplato produce the +24V

unstabilised supply. This is wired onto the motor card via
socket/fixed plug system. The +24V servos both as
a free
the relay supply and the supply to the regulators Q11 and 013.
Q11 produces +12V stabilised to meter and detectoromoduIes and
panel
also supplies Q12. Q12 produces +5.7V for
and display. Q13 produces +15V which in turn supplies Z13;
this forms an oscillator which with DC restoring components
CIS, 19 and CR6, 7 generates the -12V supply.
powerful supply than the above to accommodate
The Tf12485 has a more
the increased number of triple detector modules. The voltages
produced are the same but the increased capability is obtained
by using a switching-mode regulator to produce the +12V supply
together with larger mains transformer and reservoir capacitor.
on a Common Service Modulo
Those components are now located
side-plate as opposed to the backplato and the +12V regulator
Q11 previously used is now omitted.

All Tf12480 supplies are nominally powered by 117 or 240V AC mains.

The non-isolatod 24V DC powered option is achieved by lacing
transformer TX1 and the bridge rectifier in the power pack
Surge Current Limiting Resistor.
4.0 SYSTEM INSTALLATION

4.1 Systom Identification

After unpacking equipment check that equipment agrees the system
"Project Summary" as defined in Section 1 of this manual. This
be identified by the description label sited at roar
system can contracone
of the enclosure which will contain more t umberom was
followed by a suffix letter A,B,C
ordered.

TM2460
OCT 79
PAGE 15
4.0 SYSTEM INSTALLATION

4.1 System Identification

agrees the system
After unpacking equipment check that equipment
as defined in Section 1 of this manual. This
"Project Summary " at rear
system can be identified by the description label sited
of the enclosure which will contain the RiS contract number
C etc if more than one system was
followed by a suffix letter A,B ,
ordered.

4.2 Module Identity

The location and varying of the modules will be as stated in Table
1 "Section 1" (a) and (b) of the manual. To assist in module
identification, the readout selection pushbuttons on the front
panels have been colour coded as follows:-

All Thermocouple Detector Modules have

rod pushbuttons.

All RTD Detector Modules have green

pushbuttons.

The Motor/ Common Service Modulo has white

pushbuttons.
left to, right when
The detector modulo location runs from
the front. The ranging of any detoctor
viewing the modules from
module can be identified by examining the identity label on the
detector module
PCB and then reforing to the table on relevant
circuit diagrem . in Section 9.

4.3 Module Facility Links

as stated in the table Section
The detector modules will be linked
have been received from
1(a) of the manual . If no instructions
linked for "High/High"
the customer , modules will be supplied
trip mode and "Normally Energisod " relays with "Manual" reset.

detector
To change modulo links refer to Notes on relevant
module circuit diagram.

4.4 System Mounting

see Drawings C2504-325
For mounting details of Series TM2460
(TM2461 ) C2504-316 (TM2482) and C2504-324 (TM2485) TM2481
mounting.
and TM2482 are panel mounting and TM2485 is 19" rack
However TM2485 can be fitted with a Ri5 panel mounting bezel
typo 1024-966.

TM2480
OCT 79
PAGE 16
4.5 System Installation Wirin

For installation wiring refer to drawings C2584-251 (TM2401),

C2584-252 (TM2482 and C2584-253 (TM2405). Connections to
7142481/2 are made via Magnum screw. type terminal blocks and
to the 71`12405 via high density Met way clamp typo terminal
blocks.
In common with good wiring practice, it is most important
to segregate the sensor wiring from the output wiring to the
system by running those connections in separate cables and
wireways.

Sensor wiring to thermocouples should use twisted pairs with

overall screen grounded at one and only. Also one wire of the
thermocouple can be grounded at the sensor head as the triple
thermocouple detectors have fully isolatodfloating input
circuits.
Sensor wiring to RTD sensors should also be screened and the
screen connected to a good instrument ground at one end only.
RTD sensor wires themselves should be loft fully floating
as the "comp" load connection is common to system OV and
further grounding would disturb the 3-wire compensation.

When using thormcouplo sensors it is recommended that roar

terminal covers (supplied as standard) are fitted at all times
during operation as temperature gradients caused by draughts
etc can interfere with the operation of the cold-junction
compensation devices mounted on the roar terminal board.

System power should be wired to the 3-way terminalblock

tk
the rear of the enclosure. Before switching•on plw , chock
out wiring and consult system description label and project
summary in Section 1 to ensure system voltage is correct for
the installation. If voltage is incorrect, refer to drawing
2504-311 (TM2481/2 power supply) and dnawicg 02504-319.
(T112485 power supply) for instructions to change links on the.
power transformer in motor/common service modulo.

The system will normally be supplied with the sot points factory
set to 50% and 75i of span for the point "Alarm" and "Trip"
set point respectively. Refer to "System Calibration Suction
6.0 for calibration instructions.

5.0 OPERATING INSTRUCTIONS

Operation of the system is simple and straight forward.

After applying power to the system, all detector modules linked

for latching mode will be indicate "Alarm" and "Trip" condition.
These can be reset by pressing the "Reset" pushbutton on the
Motor /Common Service modulo.

TM2400
OCT 79
PAGE 17
5.1 Point Tomporaturo Roadout

Press the "TEMP" pushbutton on the Motor/Common Service Module-

The associated LED should light to acknowledge selection.
Press any of the point select pushbuttons the front panel of
a detector modulo. The digital indicator will road out point
temperature of the selector channel.

5.2 Point Alarm Sot'Point Readout

Press the "ALARM" pushbutton on the Motor/Common Service Modulo.

The associated LED should light to acknowledge selection. Press
any of the point select pushbuttons on the front panel of a
dotoctor module. The digital indicator will readout the sot
temperature at which the "Alarm" circuit and optional per point
relay will operate on the soloctod channel.

5.3 Point Trip Sot Point Readout

Press the "TRIP" pushbutton on the Motor/Common Service Module.

The associated LED will light to acknowledge selection. Press
any point select pushbutton on the front panel of a detector
module. The digital indicator will readout the sot temperature
at which the "Trip" circuit and optional per point relay will
operate on the selected channel.

5.4 Motor Calibration Check

Press tho"FSD"pushbutton on the Motor/Common Service Modulo.

The associated LED will light to acknowledge selection.
Prose any point select pushbutton an the front panel of a
detector module. The digital indicator should readout full
scale temperature for the selected channel.

-Prose the "ZERO" pushbutton again to extinguish tho associated

LED. The digital indicator will now readout minimum temperature
for any channel when its point select pushbutton is pressed.

If readout of "FSD" or "zero" is incorrect ooneUlt System

Calibration Section 6.

5.5 Sensor Failure Detector

When a sensor failure occurs on any channel its "ALARM" LED and
relay will be initiated. The point temperature will read downscale
for thermocouple open circuit failures and short circuit RTD
failures. The point temperature will read upscale for open
circuit RTD failures. Trip will be inhibited for all modes of
sensor failure with models linked for high and high/high operating
mode.

6.0 System Calibration

It is recommended that boforo commencing system calibration the'

reader should familiarise himself with system operation as
described in Section 5.

TM2480
OCT 79
PAGE IS
6.1 Motor Common Service Modulo Calibration

System calibration is dependent upon the motoring accuracy of

this modulo so that it is most important to chock the calibration
of this module first. This can be done with the system in
service using the following procedure:-

Section
a) Refer and/or Thermocouple
determine theJrongo(s)aof RTO
detector modules fitted.

Press "Zero" pushbutton on Common Sorvico Modulo and

chock that its LED is lit and selection is acknowledged.
Press and hold on a point selection pushbutton on any
RTO Detector Modulo. The digital indicator should now
road :, the minimum temperature of the range. Trim the
RTD "ZERO" potentiometer on the motor module to obtain
correct reading. Now press "FSD" pushbutton on common
service modulo and chock for LED acknowledgement. With
the same point select pushbutton hold on, the
cator should now road the maximum temperature
indi eraturer to
the range selected. Trim to eliminate
obtain correct reading. . Repeat
any interaction between adjustments. The RTD motor
circuit is now calibaatod.

Repeat the above procedure using a Thermocouple detector

(if fitted) to calibrate the Thermocouple motor
card
circuit adjusting Thermocouple "ZERO" and "SPAN"
potentiometers as necessary. The Thermocouple motor
circuit is now calibrated.

NOTE: The calibration of RTD and/or Thermocouple motor

an internally gonoratod +5VOC reference
circuits uses
voltage. This is "factory-set" by RV5 and should not
need adjustment.

It can be chocked with an accurate Digital Motor

(ecc 0 .05` FSD) via the test points provided onthu
common service modulo front panel.

6.2 "Alarm" and "Trip" Sat Point Calibration

This should be done after completing meter calibration chock
in 6.1. It is recommended that the system be switched
described
is made to those sot points
out of service before any adjustment
to avoid accidontial tripping of the monitored plant.

(a) Select "Alarm" set point for channel No. 1 as

described in Section 5-2.
in Channel No. 1 point select pushbutton.
( b) Press and hold
No, 1 "Alarm" sot point potentiometer
Adjust Channel
indicator roads desired alarm level.
until digital

TM2480
OCT 79
PAGE 19
 aand
(c) Select "TRIP" an the Motno o ndtor
/Co't"tfS"Trice' Madula
ropeat .procedure. 6.2(b)
to dbsirad trip level for Channel No. 1.

(c)-to sot dosirod alarm and

(d) Roppat 6. 2(a), (b) and
trip levels for all othor channels.

RTO Detector Modulo Calibration

As the calibration potantiomotors era not accessible from the

front panel, an "outrigger card" RiS part 2504-320 is required
for power -on access to the detector module.
4a) Disconnect the sensor loads from the first RTD point
resistance
within the sys t o m and replace with a precision
decade box range 0 to 1000 ohm and resolution of
+0.01 ohms.

(b) Refer ''to Project Summary Section 1, to determine

calibration range and sensor type, than use the
following table (or relevant sensor reforoncs table)
to calibrate the module.

TEMP ' 100 OHM 120 OHM

TEMP 100 OHM 120 OHM
op PLAT RIO Ni RIO
C PLAT RTO ! Ni RTD
i
60.2 53.6 - 200
-100
80 .25 86.17 - 100
- 50
100 120.00 0
0
119 .39 157.74 + .100
+ 50
138 .50 200.64 + 200
+100
+150
+200
+300
+400
157.32
175.84
212 .03
247.06
248.95
303.8
439. 44
i + 300
+ 400
+ 600
+ 800
+500 280.93 +1000
i 313.65 +1200
+600

(c) Select "TEMP" on the Motot/Common service Module.

Sot the resistance decade box to minimum for the

select pushbutton
specified range and press the point
for Channel No. 1 on the detector module. The digital
indicator should rod minimum temperature for the
. Adjust Char el No. 1 "zero" potentiometer
range
to correct any cal!. ration error.

(d) Set the resistance 'ocado box to full scale value.

The digital indicat. ; should read full scale temperature
pu s hbutto n
for the range when : hannal No . 1 selection
n tiome ter
is pressed. Adjus . Channel No. I "span" pote
to correct any calS .. 'ration error.

TM2480
OCT 79
PAGE 20
 (o) Repeat steps (c) and (d) to correct for any interaction
between "zero" and "span" potentiometer of Channel No.1.

(f) Move the decade box to sensor input No. 2 and repeat
this calibration procedure . Ropoat this procedure
for all other RTD sensors inputs to this sytom,
consulting Project Summary Section 1 for calibration
data.

6.3 Thermocouple Detector Modulo Calibration

Those modules can be calibrated using a precision DC millivolt

generator and a thermometer with a resolution of ±0.50C. Also
suitable Thermocouple Sensor reference tables will be required
such as 8S4937 or ANSI C96-2. As calibration potentiometers
are not accessible from the front panel, an "outrigger card"
RiS part 2504-320 is required for power-on access to the
detector module . Proceed as follows:-

a) Disconnect the sensor leads and replace them with the

DC generator. Place the thermometer as close to the
sensor terminal block as possible and allow the reading
to stabilise.

With the Thermocouple tables calculate the correct input

voltage for minimum span in the following manner. Using
figures from the tablo (in Absolute EMF Ref 0 C ) road
off the mV figures equivalent to a) ambient temperature
as shown on thermometer and b) minimum span temperature)
subtract "a" from "b","this is the voltage to sot the
DC generator to. -

Repeat this procedure to obtain a voltage equivalent

to maximum. temperature.

b) Select "TEMP" on the Motor/Common Service Module.

Sot the mV input signal to minimum for the specified

range of the channel to be calibrated and press its
point selection pushbutton. The digital indicator
should road minimum tomporaturo for-the range. Adjust
the channel "zero" potentiometer on the detector
module to correct any calibration error.

(c) Sot the mV input signal to maximum for the specified

range of the channel and press its point selection
pushbutton. The digital indicator should road full
scale tomporaturo for'tho range. Adjust the channel
" span " potentiometer to correct any calibration error.

(d) Repeat steps (b) and (c) to eliminate any interaction

between the channel " zor-3" and "span" controls.

-T
11'14. V UU

OCT 79
 As a final test with zero input signal (or shorted
input terminals) the digital indicator should road ambient
temperature.
an el
(e) Novo the mV source to the next thermocouple channel
to be calibrated and repeat stops (b), (c) a
for. the now channel.

System calibration is now complete. Remove the mV signal generator

(orshorting link) and reconnect the last thermocouple sensor.

Cold junction temperature variations are compensated by circuits

included in the Thermocouple Detector card and are of fixed
calibration. and cannot be adjusted.

6.4 Analogue Output Calibration

No adjustment of analogue output is possible on the detector

modules indopendant of the digital motor readout. The analogue
output signals are linear with temperature for 100 ohm RTO
platinum sensors but are not linearisod for thermocouples or
Nickel RTD sensors i.e. are directly proportional to mU
input signals.

7.0 Trouble Shooting

As the system is of modular construction, the simplest and

most effective way to isolate a fault and return the system in
by substituting spare modules and cards. It is
service is
therefore recommended that the spares listed in Section B
of the manual be hold in stock on site. Cortain faults may
still persist oven when spare parts are substituted which is
indicative of a fault external to the system.

TM2480
OCT 79
PAGE 22
 Some typical faults and their possible causes are
listed'in the following table:-
SYMPTOMS
All system LED's off, no
digital display when
readout pushbutton
pressed.
RTD or Thermocouple
channel indicates "ALARM"
evon when spare module is
substituted.
Point temperature reads
downscalo.
Low analogue output on
all three channels of
thormocoaplo detector
module . Low indicated
temperature.
Digital Display not
functioning, all other
LEDs normal.
No readout or random
display on digital
indicator on one channel
only for temperature,
Alarm and trip set
points.
No LED acknowledgement
when common service
parameter selection is
made i.e. "TEMP" otc.
to attempt to repair a modulo on site duo to
If it is necessary
lack of spares , refer to System Description in 5oction 3 and
circuit diagrams in Section 9.
POSSIBLE CAUSES
Loss of internal system
power. Chock fuse F1
at rear of common service
modulo. If fuse blows
on replacement, chock
VR5 for short and/or Q11
regulator.
Sensor failure or sensor
wiring fault.
Chock for open or short
circuit and for crossed
input wires.
Chock V-FET's QB,9 and
inverter TX1 for lack of
oscillation.
Chock Q12 for failure
and/or VR3 for short.
Chock quad.analoguo
gates 4016B on detector
modulus for leakage
across the 4K7 series
resistors. Voltage drop
should be loss than 5mV
when channel is not
selected.
Selection Fault.
Chock Z9A, B for clock
pulses and Z10 for
operation. Refer to 3.7
for operation
description.
TM2480
OCT 79
PAGE 23
 7 ` 8'.0 Recommended Spares
a The following spares are recommended to be purchased with the system
for commissioning and the first 2 years in service. The quantities
are the same for any system up to 30 points. Consult the Project
Summary section 1 to identify and determine quantity, part number
and ranging of detector modules and meter card supplied with the
system.

ITEM NO. DESCRIPTION RiS PART NO. QTY

Triple Thermocouple 2504-301 1

1
detector module'

2 Triple RTD Detector 2504-306 1

Module

3 Meter Common Service SEE 1

Card SECTION 1

4 Power Supply TM2465

a) Power Supply Card 2504-231 1

b) 21000MFD Capacitor 3512-493 (CR47-001) 1

c) Rectifier 3SB-200 4800-923 (DE-37) 1

d) Switching Transistor 4870-888 (TR-52) 1

e) Transformer 5600-036 (TX-37) 1

f) 2 Amp Fast Blow Fuse 0620-605 (FE-35) 10

g) SOOmA Q A' Surge Fuse 0620-322 (FE-36) 10

h) Heatsink Resistor DC Option

Only 4780-150 1

j) 2 Amp 'At Surge Fuse

DC Option Only 0620-606 (FE-37) 10

5 Power Supply TM2481/2

a) 6800MFD'Capacitor 3511-331 1

b) Bridge Rectifier 4820-673 1

c) Transformer 5600-032 1

d) Voltage Regulator 7805 .3136-100 1

e) Voltage Regulator 7812 3136-140 1

I 250mA 'A' Surge Fuse 240V AC
Only 0620-321 10

g) SOOmA 'A ' Surge Fuse 110V AC

Only 0620-322 10
h) Heatsink Resistor 24V DC Only 4780-150 1

6 Detector Module blank plate 2534-204 1

7 Detector Module outrigger card 2504-320 1

NOTE
A complete Power Supply Module may be purchased in preference to Items
in 4 & 5.
2504 -310 TM2481/2
2504- 309 TM2485
.9 MANUAL DRAWING INDEX

1) GENERAL DRAWINGS
TM2461 C2504-325
a) Assembly & General Details
TM2482 C2504-326
Assembly & General Details
TM2485 C2504-324
Assembly & General Details
TM2461 02504-251
b) Customer Connection
TM2462 02564-252
Customer Connection
TM2485 D2504-253
Customer Connection

2) R.T.D. INPUT SYSTEMS MODULES & CARDS

Circuit C2504-306 51-IT 1
a) Tri p le Detector Module C2504-306 S H T 2
Assembly
10OR PLT RTD
TM2461/2 C2504-310
b) Mater/C.S. General Assy
TM2485 C2504-309

TM2485 62504-319
c) Moter/C.S. Circuit & Pwr Supply
Circuit C2504-311. SILT 1
d) Meter/C.S. Card 100R PLT
or 1OR Copper RTDS Assembly C2504-311 SPIT 2

Circuit C2504-300 SHT 1

a) T r i p le Detector Module C2504-3i SIIT 2
Assembly
1OR Copper RTD
Circuit C25D4-313 SHT 1
r) Meter/C.S. PLT.RTD + Ni 120 OHM
Assembly C2504-313 SHT 2

TM24(31/2 A2504-321
g) Non Isolated D.C. Power Option
TM2485 02504-320

3) THERMOCOUPLE INPUT SYSTEMS MODULES AND CARDS

C2504-301 SHT 1
a) Triple Thermocouple Detector Circuit
Module Assembly C2504-301 SHT 2

Sensor Ranges C2504-301 SHT 3

C2504-310
Meter Comrn ;Sorvice.Gen.Assy. TM2461/2
TM2485 C2504-309
B2504-319
c) Meter Comm .CCT and PWR Supply. TM2485 .
C2504-312 SHT 1
d) Meter C/S.Type 'K' T/C Card Circuit
•Assembly C2504-312 SHT 2
C2504-314 SHT 1
a) Meter C/S. Type 'T' T/C Card Circuit
Assembly C2504-314 SHT 2
C2504-315 SHT 1
p) Meter C/S Type "J" T/C Card Circuit
Assembly C2504-315 SHT 2
C2504-316 SHT 1
9) Meter C/S Type 'E' T/C Card Circuit
Assembly C2504-3i6 SHT 2
A2504-321
h) Non Isolated D.V. Power Option TM2481/:':
TM2485 82504-320

TM240U
OCT '79
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CIRCUIT DIAGRAM DRN. is. DRG. No. REV. PART No.
NON-ISOLATED DC. POWERED rl4K 2 5L-321 0
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J I 20081 a I 22N

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- - -, RANGE CRt SIT INQ%s
1s P2-7p.-0 I
VRI
RANGE I LM329
SELECT 2i P2.6O-0 2
1 •R37
[i P2.9" [
SET POINT 2 P2.I
R29-S
:K7
R29-6
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R29-7

CCTS BIC

SELECT READOUT

NOTES
I DIAGRAM SHOWS CIRCUIT A ONLY .
COMPONENTS MARKED * ARE CONMne CIRCUITS SAC
m ... ARE IDENTICAL BUT LINK FACILITIES ARC ROCC , en...._..
_..___
^.n nos. SHUWN IN DIAGRAM FOR Z4 ARE FOR RCIJ a..rtwrls. I- -' -- a UN p INSTEAD
CIRCUITA PI N
2 FOR HIGH TR IP NODE FIT LINKS H , • Nos FOR CIRCUIT B ARC a
FCR LOS TRIP MODE FIT Z[-2 AND CIRCUIT C ARE
LINKS L
3. COMPONENTS MARKED R ARE RANGE RESISTORS
.
[.FIT LINKS M FOR LATCHING LED A RELAY , REFER TO TABLES ON SHEET 3 FOR ALL RANGING INFORMATION
REMOVE THESE LINKS IF AUTOMATIC RESET IS REQUIRED
S IF PER POINT RELAYS ARE SPECIFIED. RELAYS KIA. KIB t KIC ARE FITTED AND MUST BE LINKED AS FOLLOWS TO ACHIEVE
(o) FOR ENERWSEO RELAYS FIT LINKS If , FOR DE
- ENERGISED RELAYS FIT LINKS D.
III) FOR TRIP RELAY PER POINT FIT LINKS T FOR ALARM RELAY PER POINT FIT LINKS A DESIRED OPTII
IcI FOR HIGH I
LOW TRIP MODE WITH COMMON PER POINT RELAY FIT LINKS A t'T
IA) FOR GROUP ALARM t GROUP TRIP RELAYS EEA MC Uyl
F WIRE AS BFIOW-

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Icct Al i d
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NOT
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CHANGE TO GT2 IF .
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IN COMMON SERVICE MODULE It
6 FIT LINK N AS STANDARD -
TO ACHEIVE &LARM ONLY FOR DOWNSCALE BURNOUT WITH Hi ALARM & TRIP MODES.
ON SENSOR FAILURE 1 FIT LINK P FOR UPSCALE BURNOUT WITH ALARM A TRIP )
7 STANDARD ANALOGUE OUTPUT IS I-S+DC. FOR 0-Sv DC OUTPUT FIT LINK Z

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CI RC UIT DIAGRAM OF DRN 1S ORO. NK SHTI OF 3 REV PART N^
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 IC100 IC 100C
ELECTRONIC TIMERS
APPLICATION NOTES & WIRING DIAGRAMS FOR IC100 RANGE
The IC100 is a new electronic timer which uses the latest CMOS technology to give an accurate timer with all the functions
high frequency oscillator which is
available to allow easy integration into industrial control systems. The timing circuit uses a stable as well as
divided down to give the desired time out period. This method gives a high repeat accuracy unaffected by pause time
improved rejection of external interference sources.
The different basic functions are obtained by minor component variations on a common printed circuit board. Operation of these
is described below.
1. 11 PIN TIMERS
1.1 Supply initiated operation interval, Fig. 1, Mode 3a.
There is a permanent link between pins 6 and 7. Connect the supply and the relay will be energised and timing will
commence within 30mS. At time out the relay is deenergised and contacts change over within 20mS. If the supply is
interrupted for a period greater than the pause time, approx. 100mS, a new full timing period will be initiated. The timing
is unaffected by supply interruptions of less than this pause time, although the relay will momentarily drop out for
interruptions between 20-loomSvMn request, timers can also be supplied without an internal link between pins 6 and 7.

> lOOmS

TIME't' t

SUPPLY INITIATED INTERVAL TIMING. FIG. 1

1.2 Contact Initiated operation interval, Fig . 2, Mode 3b and 3c.

the timer does not start nor the relay energise until a contact between pins 6 and 7 is made for at
When supply is connected , The contact closure can be an impulse or a continuous closure for a time In
least 1 mS, then operation is as para . 1.1 above . When open, the voltage between pins 6 and 7
excess of the set time . Further contact closures during time outThe are ignored .
. 0.5mA. timer will be reset if a supply break of greater than
is approx . 12v d . c. and current when closed is approx
lOOm5 occurs during timing.
>l oo mS
ON
SUPPLY OFF
>1mS
ON
CONTACT OFF

OUTPUT
ON
OFF
J t u t
CONTACT INITIATED INTERVAL. FIG. 2

1.3 Supply initiated operation delay, Fig . 1, Mode Ia.

Connect to supply, the relay will remain deenergised and timing will
Connect a permanent link across pins 6 and 7 . . If the supply is inter-
commence within 30mS . At time out the relay is energised and contacts change over within 20mS
10omS, a new full timing period will be initiated . The timing is
nspted for a period greater than the pause time, approx .
unaffected by interruptions of less than this pause time. On request, timers can aim be supplied without an internal link
between pins 6 and 7.

>loomS
ON
SUPPLY
OFF

ON , t
t
OUTPUT OFF
SUPPLY INITIATED DELAY. FIG.1
1.4 Contact Initiated operation delay , Fig. 2, Mode tb and tc.
the timer does not start until a contact between pins 6 and 7 is made for at least 1 mS, then
When the supply is connected , can be an impulse or a continuous closure for a time in excess of the
operation is as para. 1.3 above . The contact closure voltagebetween
k Pi s 6
set time. Further of greater than n lOOms occurs 12v
c. and the currennttnwhen closed is approx. 0.SmA. The timer will e reset if a supply
d
during or after timing . > IOOMS

ON
SUPPLY
OFF
>lmS
ON
CONTACT OFF

ON
tit -t--I L_
OUTPUT OFF
CONTACT INITIATED DELAY. FIG. 2
 ON
SUPPLY
OFF
ON
CONTACT OFF

ON
OUTPUT u
OFF t LI
DELAY TO OFF CONTACT INITIATED. FIG. 2
1.6 Recyling operation ,
Fig. 3, Made 4b and Sb.
When supply is connected timing commences within 30mS
factory set to 100mS ) and a new timing . After the
period starts when the relay isset time the relay is energised
de-energised . The time T can for a time T ( normally
period between 50mS and 30 hours.
be factory set to any
An alternative factory option is available where the relay is energised during timing and de-energised for the period T. If
desired the recycling timer can be reset to the start of its time period
restarting when the contact is opened ( Fig. 2). by closing a contact between pins 6 and 7, timing

ON
SUPPLY
OFF
ON
CONTACT OFF OPTIONAL RESET
ON
OUTPUT A
OR OFF
4b
OUTPUT B ON
5b
OFF

RECYCLING (WITH OPTIONAL RESET). FIG. 3

1.7 Flip Flop or Cycle Timer,
IC100C, Mode 4, and Sa Ask
This timerishas
Operation two time
exactly control potentiometers
as described in para . available to control the ON and OFF times of the relay independently,
second time control . 1.6 above, except that the time T which
was fact ory set Is now controlled by the
Bdih the ON
be achieved a for the raccycling andby
timer OFF times can be in any 16100 time range up to and including 30 hours
closing • a contact across pins 6 and 7 . Reset can
. ( Fig. 2).

ON
SUPPLY
OFF
ON
CONTACT
OFF
tt
_. Op OPTIONAL RESET
ON t2
OUTPUT A
ncc
^- 'a
ti
ON r-, t2
OUTPUT n Sa

CYCLE TIMER ( FLIP FLOP )

WITH-OPTIONAL RESET

2. 'OPTIONS AVAILABLE
21 Recycling NO Cycle Timed
t)ontplementary relay.operation is possible
, i.e. Delayed or Immediate operation
-2.2 -Single pole C/Oreley ,'FiFit. 4 , see function 1.6 above.
-Wit h 16A switchingor5A continuous rating
.
on the side label . AI( the functions described i The contact connections are to pins 1, 3 and 4 of the magnal plu g
a s s h own
2. 3 Remote ti m i n pares, 1.1 and 1.7 above or 2.3 and 2.5 below are available .
ng control with supply Initiation, Fig. S
, A Q Megohm ± 1% p ot ent i
whetetshould
"§IA Slockwise direction be used connected as a variable resistor so that resistance Increases when the s
. This resistor should be p i n dl e
transients is desired a tw nteened cable (e . g . connected to pins 5 and 6 of the two .
RS Components type 367-224 ) If maximum rejecti on o f
pin 7 and not connected at the potentiometer end . N can be used with the screen connected t o
from all Powetc (rcuit;, ote it is desirable to route this screened cable as far away
tryler no circumstances must the screen be connects to an other as possible
24 Remote timdsyeontrol with contact initiation , Frs. B Y point than pin 7.
"Ibi s combination is only available with a single pole
c% relay. The contact is to be connects between pins 7 and 8
maximum rejection of transients is required a . If
2.5 Transient protection ^)+yscreens
_^^^^ cable can be used connectedys details in para .
2.3 above.
Thedesign of the IC100 s eri es t i mers
ensu di,
r
applications where severe transients cad occur ^bpdbij0^tion
a verist pf supply and electromagnetic induced transients .
For use in
or can be fitted internally to give further rejection .
It 1PIN BASE TIMEcS Order code -/T.
Basically these timers are identical in operation to ti
means that there are not so tryme options Pl,eiar1Bty but the restriction in the number of output /input pins
at Two polerolay vs ntons 8 pin araiiable, *1 e ere Iwo possible main arrangements:
1 11
3. 1 . 1 S upply initiated interval Fig
.7.
These timers can only. Fig. 7e stsgplY initid
3.1.2 Supply initiate delay. Fig. 7 OOMtion. It operates "rattly as in para. 1.1 above.
As with the interval version these tsmetI'ces ohly provide supply initiated operation.
1.3 above. 7 It operates exactly as in para.
3.1.3 Recyling^ Fig.7 "'.
When the ?bpply is connected, timing conimenceaanblifn 30mS. After the set time the
(normally factoryaet to 10OmS) and a new jimirg period starts when the relay is dee relay is energised for a time T
factory set to any period between 50mSand,361purs, rrorgised , The time T can be
An alternative
period T factory set option isasypable.where the relay is energise
 3.2 Single pole versions 8 pin
3.2.1 Supply initiated operation interval , Fig. 8
Operation is exactly as described in para . 1.1 above except that pins 5 and 6 are to be linked by the user . Timers
can also be supplied with an internal link between pins 5 and 6 in which case they can only provide the supply
initiated mode of operation.
3.2.2 Contact initiated operation interval , Fig. 9
Operation is exactly as described in para . 1.2 above except that the contact Is made between pins 5 and 6.
3.2.3 Supply initiated operation delay, Fig. 8
Operation is exactly as described in para. 1.3 above except that pins 5 and 6 are permanently linked by the user.
Timers can also be supplied with an internal link between pins 5 and 6 in which case they can only provide the
supply initiated mode of operation.
3.2.4 Contact initiated operation delay, Fig. 9
Operation is exactly as described in para. 1.4 above except that the contact is made between pins 5 and 6.
3.2.5 Delay to off from contact opening, Fig. 9
Operation is exactly as described in para . 1.5 above except that the contact is made between pins 5 and 6.
3.2.6 Recycling operation , Fig. 10
Operation is exactly as described in para . 1.6 above except that to reset the timer the contact must be closed
between pins 5 and 6 ( Fig. 9).
3.2.7 Flip-flop or cycle timer, Fig. 10
Operation is exactly as described in para . 1.7 above except that to reset the timer the contact must be closed
between pins 5 and 6 ( Fig. 9).
3.3 Options available
3.3.1 Recycling and Cycle Timer
Complementary relay operation is possible , i.e. Delayed or Immediate operation , see function 1.6 above.
3.3.2 Remote timing control , Fig. 11
A 1 Megohm ± 1% potentiometer should be used connected as a variable resistor so that resistance increases when the
spindle is rotated in a clockwise direction . This resistor should be connected to pins 6 and 8 of the base. If
maximum rejection of transients is desired a twin screened cable ( e.g. RS Components type 367224) can be
used with the screen connected to pin 5 and not connected at the potentiometer end. Note it is desirable to route
this screened cable as far away as possible from all power circuits . Under no circumstances must the screen be
connected to any other point than pin 5.
3.3.3 Transient protection
The design of the IC100 series timers ensures good rejection of supply and electromagnetic induced transients. For
use in applications where severe transients can occur a varistor can be fitted internally to give further rejection.
r Order code -/T.

NEUTRAL
or +ve J SUPPLY ( or -ve
FIG.$ SUPPLY INITIATED
FIG.7 SUPPLY INITIATED INTERVAL OR DELAY
INTERVAL, DELAY,
RECYCLING, CYCLE
TIMER -2 POLE 8 PIN.

FIG.9 CONTACT INITIATED

INTERVAL, DELAY, DELAY
TO OFF, RECYCLING WITH
RESET, CYCLE TIMER WITH
RESET.
 EXTERNAL CONNECTIONS

FIG.2 CONTACT INITIATED INTERVAL,

DELAY, DELAY TO OFF,
FIG. 1 SUPPLY INITIATED RECYCLING WITH RESET, CYCLE
INTERVAL OR DELAY TIMER WITH RESET.

LINE NEUTRAL
or,+ve SUPPLY or,,-ve
FIG.4 SINGLE POLE RELAY.
FUNCTIONS REQUIRED
FIG. 3 RECYCLING OR CONNECTED AS IN FIGS.
.CYCLE TIMER. 1,2,3,5,6:

I-------%SCREEN

LINE NEUTRAL,,:
or ±ve 'Su
-PP^LY°lot-ye
FTG, 6 REMOTE TIMING CONTROL.
FIG. 5 REMOTE TIMING CONTROL FOR -NIT-H CONTACT INITIATION,
SUPPLY I NITFATED INTERVAL DELAY , INTERVAL, D/OFF,
D E LA? ,AND".# E C'f& I N G. RECYCLING.

ELECTRICAL REMOTE CONTROL CO. LIMITED,

 CA2 D, LP .-D
i
Telemecanique'
0

d range DC control
The electromagnets
The control relays and contactors incorporate a control circuit for DC or AC rectified supply .
are designed for full voltage operation and the coils are continuously rated.
No economy resistor is required. AC control "d" range.
The control relays and power poles are identical to those of the corresponding
Control relay characteristics:
-High DC switching capacity.
-Double break contacts.
-Long contact travel.
-Ventilated contact chambers.
d" range accept the numerous accessories that have been designed for the whole
All the units of the DC new "
Instantaneous and time delay auxiliary contact blocks.
AC range: - Suppressor block that clips on the front of the contactor.
-
-Fuse holders.
- Thermal overload relays and their lead sealing kits, etc.
Two types of coil covering the range12 to 600V DC:
-One type for normal use with "All climates" (TC treatment) or for hot and
humid conditions (Treatment TH).
One type for special applications ( large voltage drops , prolonged supply
surges, extreme variations of temperature , long cable runs, etc.)
These coils are also suitable for use in hot and humid conditions
(TreatmentTH).
Average coil consumptionatUn ( inrush andsealed).
-ForCA2-D,LP1-D12andLP2- 12., ,
Standardtoils: B W.
-Wide range coils : 6.5W.
-For LP1 -D16 andD25 , LP2t16and 07$'
Standard coils: It W. 3y,
-Wide rargecoils:BW.
The wide range coils enable operation w$hiarge voltage and temperature
variations; their voltage range varies fromp ;76Uno1 . 25 Un at an ambient
temperature of 70 °C.. `:" -
Simple and quick coil replacement by removing the contact housing from the contactor
Two mounting alternatives : - On 50-60 mm verticallking centrea.
- Directly onto 35 mm omega mounting rail.

Body Contact terminals

Contact assembly support

Moving magnet
 N
N
y

ay.P.i.'wasaov