Contents

1 Drawings
Dimension drawing alternator A102 DG274-242A
Dimension drawing alternator A202 DG274-241A
Rotor drawing R0990126A
Lifting Advice KR31549.17

2 Circuit Diagram
Circuit diagram with legend K9L10081A

3 Installation, Service and Maintenance Manual

DSG / DIG AC Generators: ISM Manual
Check list

4 Regulator Descriptions
Voltage regulator Cosimat N+

5 Cooler
Description of Double Tube closed-circuit Cooler

6 Replacement Parts
List of Recommended Replacement Parts

7 Technical Data
Technical Data
EC declaration of conformity
Test report 8131663A002

8 Contact Details
Customer Contact List

Wärtsilä Qiyao Diesel Co. Ltd 09/2013

Your order: 0000011236
Your project: KUMA
AvK Order no. 8131663A002
Drawings
Circuit Diagram
APPROVED DOCUMENT
Seite 1 Legende zum Schaltbild Nr. Legend to Circuit Diagram No.
Page 1 K 8**.*.** (K9******) K 8**.*.** (K9******)

F1, F2 Schutzschalter für G3 Protection switch for G3

NUR IM STILLSTAND BETÄTIGEN ONLY SWITCH ON AT STANDSTILL
G1 Hauptmaschine Main machine
G2 Erregermaschine Exciter machine
G3 Hilfserregerwicklungen Auxiliary exciter windings
Q1 Schutzschalter Protection switch
NUR IM STILLSTAND BETÄTIGEN SWITCH ON ONLY AT STANDSTILL
31-32 Meldung 31-32 Signal
R11 Rotierender Varistor Rotating varistor
R12 Rotierender Schutzwiderstand Rotating protection resistor
R21 Vorwiderstand Serial resistor
R2 Vorwiderstand Serial resistor
T24 Spannungswandler für Regler Voltage transformer for AVR
BEI GEÖFFNETEM STERNPUNKT VON G1 DISCONNECT IF STARPOINT OF G1 IS
UNBEDINGT ABKLEMMEN OPEN
T25-28 Spannungswandler Voltage transformer
T30, 31 Spannungswandler für G3 Voltage transformer for G3
T32 Spannungswandler für G3 mit integriertem Voltage transformer for G3 with integrated
Schutzschalter F1 protection switch F1
F1 - nur im Stillstand betätigen! F1 - only switch at standstill!
V1 Rotierende Gleichrichter Rotating rectifiers
X1 Hauptklemmen Main terminals
X2-20 Klemmleiste Terminal strip

U1 Spannungsregler Cosimat N Alternator voltage regulator Cosimat N

R3 Unterdrehzahlschutz R3 Underspeed protection
R4 Interner Sollwert R4 Internal voltage setting
R1 P-Anteil R1 P-Part
S1 I-Anteil S1 I-Part
R7 Statikeinstellung R7 Droop adjustment
R6 Statikwandleranpassung R6 Droop transformer adaption
R1 Sollwertpot. Generator Spannung (R = 500 Ω) Alternator voltage adjuster (R = 500 Ω)
T6 Statikwandler Droop transformer
' ACHTUNG: Bei Regler lose: Regleranschluß CAUTION: AVR loose supply:AVR connection
Drehrichtung rechts: Rotation clockwise:
Leiste X2 Regler Terminal X2 AVR
U ⇒ U U ⇒ U
V ⇒ V V ⇒ V
W ⇒ W W ⇒ W
Drehrichtung links: Rotation counter clockwise:
Leiste X2 Regler Terminal X2 AVR
W ⇒ U W ⇒ U
V ⇒ V V ⇒ V
U ⇒ W U ⇒ W

Schnellentregung: Quick de-excitation:

Brücken UH1-24 und WH1-14 öffnen Open bridges UH1-24 and WH1-14

Entregungsschalter: 220 V AC De-excitation switch: 220 V AC

(nicht AvK Lieferumfang) 10 A (not AvK supply) 10 A

---- Verbindungen außerhalb des Generators Connections outside the alternator

Erstellt am: 01.08.2011 Issued on: 01.08.2011
AvK geprüft von: Cornel Buzatu Checked by: Cornel Buzatu
Revision Nr.: 4 Revision No.: 4
Seite 2 Legende zum Schaltbild Nr. Legend to Circuit Diagram No.
Page 2 K 8**.*.** (K9******) K 8**.*.** (K9******)

ZUBEHÖR ACCESSORIES
Widerstandsthermometer PT100 Resistance Thermometer PT100
A1-12 Statorwicklung Stator winding
Phase U: 1, 4, 7, 10 Phase U: 1, 4, 7, 10
Phase V: 2, 5, 8,11 Phase V: 2, 5, 8, 11
Phase W: 3, 6, 9, 12 Phase W: 3, 6, 9, 12
A13, 14 Lager, B-Seite Bearing, NDE
A15, 16 Lager, A-Seite Bearing, DE
A20, 21 Generator Zuluft Alternator air inlet
A22, 23 Generator Abluft Alternator air outlet
A24, 26 Statorblechpaket Stator core
A27/28 Sekundär Kühlmittel EIN/AUS Secondary Cooling agent inlet / outlet
AR1-24 Überspannungsableiter Overvoltage arrester

C1 Entstörkondensator Interference Suppression Capacitor

Lagerschadendetektor Bearing damage detector

D1, 2 B-Seite NDE
D3, 4 A-Seite DE

H, H1-5 Stillstandsheizung Anti condensation heater

L1-4 Leckageanzeiger Kühler Leakage detector cooler

LW1-4 Luftfilterüberwachung Air filter supervision

SR1-6 Schleifring Slip ring

STW1-4 Drehzahlmesser Speed transmittor

Stromwandler Current Transformer

T8 für Stand-by-Regler for Stand-by-unit
T14-16 Für Messung (M), Schutz (P) For Measuring (M), Protection (P)
Kern Nr. 1: X5, 1-6 (M) Core No. 1: X5, 1-6 (M)
Kern Nr. 2: X5, 7-12 (P) Core No. 2: X5, 7-12 (P)
Kern Nr. 3: X5, 13-18 (P) Core No. 3: X5, 13-18 (P)
T17-22 Messung Measuring

PTC Temperaturfühler PTC Temperature Sensor

TF1, 3 Statorwicklung, Warnung Stator winding, warning
TF5, 7 Statorwicklung, Warnung Stator winding, warning
TF2, 4 Statorwicklung, Abschaltung Stator winding, shut down
TF6, 8 Statorwicklung, Abschaltung Stator winding, shut down

TF11, 13 Lager B-Seite, Warnung Bearing, NDE, Warning

TF15, 17 Lager A-Seite, Warnung Bearing, DE, Warning
TF12, 14 Lager B-Seite, Abschaltung Bearing, NDE, Shut down
TF16, 18 Lager A-Seite, Abschaltung Bearing, DE, Shut down

Thermometer Thermometer
TF20, 21 Lager, B-Seite Bearing, NDE
TF22, 23 Lager, A-Seite Bearing, DE
TF24, 25 Generator Zuluft Alternator air inlet
TF26, 27 Generator Abluft Alternator air outlet
WW1-4 Wasserdurchflußwächter Water flow indicator
Z1 Entstörfilter (Funkstörgrad “K“) Interference filter (R.I.S. degree “K“)

Erstellt am: 01.08.2011 Issued on: 01.08.2011

AvK geprüft von: Cornel Buzatu Checked by: Cornel Buzatu
Revision Nr.: 4 Revision No.: 4
Seite 3 Legende zum Schaltbild Nr. Legend to Circuit Diagram No.
Page 3 K 8**.*.** (K9******) K 8**.*.** (K9******)

Reglerzubehör AVR Accessories

U2 Cos phi Regler Cos Power factor regulator
R1 Cos phi Bereich R1 Power factor range
R2 Minimale Erregung R2 Minimum excitation
R3 Strombegrenzung R3 Current limitation
R2 Cos phi Steller (R = 5 KΩ) Power factor adjuster (R = 5 KΩ)
S2 Schalter, nicht AvK Lieferung Switch, not AvK supply
a-Spannungsreglerbetrieb a-voltage regulation
b-cos phi Regelung b-power factor regulation
T7 Stromwandler für U2 Current transformer for U2

U3 Stromregler SR2-80 Current regulator SR2-80

R1 Stromsollwert R1 Desired current value
R2 P-Parameter R2 P-Parameter
R3 I-Parameter R3 I-Parameter
R3 Stromsollwertsteller (R = 5 kΩ) Desired current value adjuster (R = 5 kΩ)
S3 Schalter, nicht AvK Lieferung Switch, not AvK supply
a-Spannungsreglerbetrieb a-voltage regulation
b-Stromregelung b-Current regulation
T9, 10 Stromwandler für U3 Current transformer for U3

U4 Baustein U/F Kennlinie UF Unit U/F characteristic UF

R1 Frequenz Feinjustierung R1 Frequency fine adjustment
R2 Steilheit R2 Steepness
S4 Schalter, nicht AvK Lieferung Switch, not AvK supply
a-Spannungsreglerbetrieb a-voltage regulation
b-U/F Kennlinienregelung b-U/F Regulation

U5 Manuelle Spannungssteuerung Manual voltage control

T20 Transformator T20 Transformer
V21 Gleichrichter V21 Rectifier
S5 Umschalter S5 Switch
Pos. 1: Manuelle Steuerung Pos. 1: Manual control
Pos. 2: Manuelle Steuerung überlagert mit Regler Pos. 2: Manual control together with AVR
Pos. 3: Spannungsregler Pos. 3: AVR

Achtung: Caution:
In Pos. 2 muß die Übernahme von Reglerbetrieb in In Pos. 2 take over from regulator to manual
manuelle Steuerung erfolgen, danach Umschaltung control: then switch to Pos. 1.
nach Pos. 1
SCHUTZ GEGEN ÜBERSPANNUNG IN POS. 1 PROTECTION AGAINST OVERVOLTAGE IN
UNBEDINGT VORSEHEN! POS. 1 IN ANY CASE TO PROVIDE!

U6 Erregersystemüberwachung TO 109/110.1 Excitation system control TO 109/110.1

Schaltbild Z 2767.1 Connection diagram Z 2767.1

Fehlermeldung muß zur Entregung und Alarm must lead to de-excitation and switch off
Abschaltung des Generators führen ! of the alternator

V30 Zündbaustein Ignition module

Erstellt am: 01.08.2011 Issued on: 01.08.2011

AvK geprüft von: Cornel Buzatu Checked by: Cornel Buzatu
Revision Nr.: 4 Revision No.: 4
Seite 4 Legende zum Schaltbild Nr. Legend to Circuit Diagram No.
Page 4 K 8**.*.** (K9******) K 8**.*.** (K9******)

U7 Erregerstrombegrenzer ER1 Excitation current limiter ER1

I < Strombereich 0.5 - 2.0 A I < current range 0.5 - 2.0 A
I > Strombereich 2.0 - 5.75 A I > current range 2.0 - 5.75 A
Kontaktbelastung (1-8): Contact loading (1-8):
max. Schaltspannung: 380 VAC max. switch voltage: 380 VAC
max. Schaltstrom: 8 AAC max. switch current: 8 AAC
Schaltleistung: 150 W / 2000 VA Switch power: 150 W / 2000 VA
Inselbetrieb: siehe Beschreibung ER1, Punkt 7.1 For single operation, see description ER1, 7.1
S7 Schalter, nicht AvK Lieferung Switch, not AvK supply
a) Inselbetrieb a) Single operation
b) Parallelbetrieb b) Parallel operation
(Kontakte potentiallos) (Contacts without potential)

U8 Erweiterter Spannungsstellbereich ES für Extended voltage adjustment range ES for

Cosimat N Cosimat N
S8
Schalter, nicht AvK Lieferung Switch, not AvK supply
a) Betrieb mit U1 a) Operation with U1
b) Betrieb mit U8 b) Operation with U8
R8
Spannungssollwertsteller (R = 10 KΩ) Voltage setting rheostat (R = 10 KΩ)

U9 Tiefpaßfilter Low pass filter module

U10 Zusatzbaustein QR1 Additional unit QR1

U11 Zusatzbaustein KP Additional unit KP

U12 Zusatzbaustein EI Additional unit EI

U13 Zusatzbaustein UDC Additional unit UDC

U14 Zusatzbaustein UE Additional unit UE

U15 Zusatzbaustein MB Additional unit MB

U16 Zusatzbaustein QPF, QPF-NK Additional unit QPF, QPF-NK

U17 Erregerstromüberwachungsrelais, GIW1 Excitation current supervision relay GIW1

Versorgung von Netz Supply from mains
(Spannungsbereiche s. Gerätebeschreibung) (voltage levels see equipment description)

U18 Spannungsabgleicher; CUN1 System Voltage Adjuster; CUN1

S18 Schalter, Kontakte (24 V, 20 mA GS), S18 Switch, Contacts (24 V, 20 mA, DS) without
potentialfrei, nicht AvK Lieferung, Pos. b, potential, not AvK supply, Pos. b, Release U18
Freigabe U18
Bei Anschluß an das Netz (L1, L3) auf Drehfeld At connection to the mains (L1, L3) pay
achten attention to the phase rotation.

U19 XE2 Gleichstromrelais, Erregerausfallschutz XE2-DC Relay, Excitation protection

Schalttafelmontage Location: Switchboard
Spannungsversorgung: Siehe Beschreibung Voltage supply: See description
(ersetzt Gerät XE1) (replacement of device XE1)
Erstellt am: 01.08.2011 Issued on: 01.08.2011
AvK geprüft von: Cornel Buzatu Checked by: Cornel Buzatu
Revision Nr.: 4 Revision No.: 4
Seite 8 Legende zum Schaltbild Nr. Legend to Circuit Diagram No.
Page 8 K 8**.*.** (K9******) K 8**.*.** (K9******)

U16 QPF (QPF-NK) Multifunktions QPF (QPF-NK) Multifunction Additional Units

Zusatzbausteine

Regelung der Netzkoppelstelle (QPF-NK) Control of the network connecting point

(QPF-NK)
-- Spannungsversorgung für QPF (QPF-NK): Voltage supply for QPF (QPF-NK):
80 V oder 220 V WS 80 V or 220 V AC

R16 (R2) Sollwertpotentiometer für QPF (QPF-NK), 5 kΩ Set point potentiometer for QPF (QPF-NK),5kΩ

S16 (S) Schalter (S Simultanschalter) Switch (S Simultaneous switch)

nicht AvK Lieferumfang No AvK supply
QPF (QPF-NK) Betrieb: 13-14 geschlossen QPF (QPF-NK) Function: 13-14 closed

T12 Wandler für Strommessung Phase V (für QPF) CT for current measurement Phase V (for QPF)

T13 (T13.1) Wandler für Strommessung, CT for current measurement,

Phase V, exklusiv für QPF-NK Phase V, exclusive for QPF-NK
Sekundär mit Bürde (Widerstand) für 7 V WS bei Secondary with burden (resistance) for 7 V AC at
Primärnennstrom (evtl. Zwischenwandler T13.1) nominal current in the primary (eventually
intermediar CT T13.1)

T25 Wandler für Spannungsmessung / VT for voltage measurement

Phasen U-W (100-500 V WS) Phase U-W (100 - 500 V AC)
Verzerrungsfreie Meßspannung Measuring voltage without distorsion
(nicht AvK Lieferumfang) (No AvK supply)
Achtung: Bei Anschluß an QPF-NK, Drehrichtung Caution: At connection to QPF-NK, notice the
beachten (Siehe Legende Seite 1) direction of rotation (See legend page 1)

U17 GIW1 Erregerstromüberwachungsrelais GIW1 Exciter current supervision relay

Spannungsversorgung: fremd Voltage supply: from outside

-- QPF Einbau in den Generatoren oder lose QPF Mounting in the alternators or loose
-- T12 Einbau in den Genos T12, mounting in the generators
QPF-NK, GIW1, R1, R2, S16 (S) QPF-NK, GIW1, R1, R2, S16 (S)
Einbau in der Schaltanlage Mounting in the switchboard

Bemerkungen: Remarks:

-- Regelung erfolgt ab 1 V sekundär T13 (T13.1), Control begins from 1 V at secondary of T13
d.h. 15% Sogstrom bezogen auf Primärnennstrom (T13.1); that is 15% absorbed current (from the
von T13 (T13.1) network) refer to primary rating current of T13
(T13.1)

Eine eventuell vorhandene statische If existing, the compensating circuit (condenser

Kompensationsanlage (Kondensatorbatterie) ist auf group) is to be set on a fixed value (Regulating
festen Wert einzustellen (Keine Regulierung during operation is not possible.)
während des Betriebs möglich)

Erstellt am: 01.08.2011 Issued on: 01.08.2011

AvK geprüft von: Cornel Buzatu Checked by: Cornel Buzatu
Revision Nr.: 4 Revision No.: 4
Installation, Service and Maintenance
Manual
DSG/DIG AC Generators
Installation, Service and Maintenance

English
Original Instructions 6-2013 A046V044 (Issue 1)
Table of Contents
1. FOREWORD............................................................................................................................. 1
1.1 General.............................................................................................................................. 1
1.2 The Manual........................................................................................................................ 1
1.3 Legal.................................................................................................................................. 2

2. SAFETY PRECAUTIONS......................................................................................................... 3
2.1 Safety Information and Notices used in this manual......................................................... 3
2.2 Skill Requirements of Personnel ....................................................................................... 3
2.3 Risk Assessment ............................................................................................................... 3
2.4 Personal Protective Equipment (PPE) .............................................................................. 3
2.5 Grounding.......................................................................................................................... 4
2.6 Noise ................................................................................................................................. 4
2.7 Electrical Equipment.......................................................................................................... 4
2.7.1 Work on Electrical Equipment ................................................................................ 5
2.8 Lock Out/Tag Out .............................................................................................................. 5
2.9 Lifting ................................................................................................................................. 5
2.10 Generator Operating Areas ............................................................................................. 6
2.11 Safety Information Signs ................................................................................................. 6
2.11.1 Hazard Warning Labels ........................................................................................ 6
2.12 Oils and Grease .............................................................................................................. 7
2.12.1 Solvents and Substances Containing Solvents.................................................... 7
2.13 General Guidance ........................................................................................................... 8
2.13.1 General Safety Instructions .................................................................................. 8
2.13.2 General Guidance for Use.................................................................................. 10

3. SAFETY DIRECTIVES AND STANDARDS ........................................................................... 11

3.1 European Directives: EC Declaration of Conformity for Incorporation ............................ 11

4. INTRODUCTION .................................................................................................................... 13
4.1 Serial Number.................................................................................................................. 13
4.2 Rating Plate ..................................................................................................................... 13
4.3 Important Remarks .......................................................................................................... 13
4.4 Liability, Warranty and Guarantee................................................................................... 14
4.5 Intended Use ................................................................................................................... 15
4.5.1 Operating Conditions............................................................................................ 15
4.6 Documentation ................................................................................................................ 16
4.6.1 Additional Information........................................................................................... 16
4.6.2 Information Not Included in the Documentation ................................................... 16

5. TRANSPORTATION, STORAGE AND CORROSION PROTECTION .................................. 17

5.1 Transportation and Packaging ........................................................................................ 17
5.1.1 General ................................................................................................................. 17
5.1.2 General Information for Roller bearings ............................................................... 17
5.1.3 General Information for Air-Water Coolers........................................................... 17
5.1.4 Packaging ............................................................................................................. 17
5.1.5 During Transport................................................................................................... 17
5.1.6 Unpacking Checks/Items supplied ....................................................................... 18

A046V044 (Issue 1) i
Table of Contents 6-2013

5.1.7 Inspection on Arrival ............................................................................................. 19

5.1.8 Inspection on Unpacking ...................................................................................... 19
5.2 Storage ............................................................................................................................ 19
5.2.1 Storage in a Suitable Room (Less Than 6 Months) ............................................. 19
5.2.2 Storage in Unsuitable Conditions For Less Than 2 Months................................. 20
5.2.3 Storage in a Suitable Room (Longer than 6 Months)........................................... 20
5.3 Protect Against Corrosion ............................................................................................... 21
5.3.1 Bare Surfaces....................................................................................................... 21
5.3.2 Roller Bearings ..................................................................................................... 21
5.3.3 Air-air Cooler ........................................................................................................ 21
5.3.4 Air-water Cooler.................................................................................................... 22
5.3.5 Customer Connection Openings .......................................................................... 22
5.4 Remove Corrosion Protection ......................................................................................... 22
5.4.1 Roller Bearings ..................................................................................................... 22
5.4.2 Cooler ................................................................................................................... 22
5.4.3 Condensed Water Drain ....................................................................................... 23
5.5 Oil Drain Points ............................................................................................................... 23

6. INSTALLATION AND ALIGNMENT........................................................................................ 25

6.1 General............................................................................................................................ 25
6.2 Preparation of the Generator........................................................................................... 25
6.2.1 Generators with Roller Bearings........................................................................... 25
6.2.2 Recommendations for Coupling Assembly........................................................... 26
6.3 Mounting Design.............................................................................................................. 26
6.3.1 General ................................................................................................................. 26
6.3.2 Mounting Forces................................................................................................... 27
6.3.3 Mounting on Ships................................................................................................ 27
6.3.4 Installation on Concrete Foundations ................................................................... 28
6.3.5 Installation on Steel Foundation ........................................................................... 29
6.4 Align the Prime Mover and Generator............................................................................. 30
6.4.1 General ................................................................................................................. 30
6.4.2 Theory of Alignment ............................................................................................. 30
6.4.3 Compensate for Thermal Expansion .................................................................... 31
6.4.4 Assemble the Coupling Halves............................................................................. 32
6.4.5 Coarse Alignment ................................................................................................. 33
6.4.6 Final Alignment..................................................................................................... 33
6.5 Fit the Dowel Pins ........................................................................................................... 36
6.6 Measures for Delayed Commissioning............................................................................ 36

7. MECHANICAL AND ELECTRICAL CONNECTIONS............................................................. 37

7.1 General............................................................................................................................ 37
7.2 Mechanical Connections ................................................................................................. 37
7.2.1 Cooling Air Connections ....................................................................................... 37
7.2.2 Connect Cooling Water ........................................................................................ 38
7.3 Connect Vibration Sensors.............................................................................................. 38
7.3.1 Roller Bearings ..................................................................................................... 38
7.4 Electrical Installation........................................................................................................ 38
7.4.1 General Information.............................................................................................. 38
7.4.2 Safety.................................................................................................................... 38
7.4.3 Moisture ................................................................................................................ 39

ii A046V044 (Issue 1)
6-2013 Table of Contents

7.4.4 Insulation Resistance ........................................................................................... 39

7.4.5 Main Terminal Box................................................................................................ 40
7.4.6 Auxiliary Terminal Boxes ...................................................................................... 40
7.4.7 Isolation Distances for the Primary Line Connections.......................................... 40
7.4.8 Primary Line Cables ............................................................................................. 40
7.5 Criteria That Affect the Output Power ............................................................................. 43
7.5.1 Design Criteria...................................................................................................... 43
7.5.2 Effect of Coolant Temperature ............................................................................. 43
7.5.3 Effect of Installation Altitude ................................................................................. 44
7.5.4 Effect of Power Factor Cos Phi ............................................................................ 44
7.6 Electrical Behavior........................................................................................................... 45
7.6.1 Principle of Operation ........................................................................................... 45
7.6.2 Voltage Regulator................................................................................................. 46
7.6.3 Self-excitation, De-excitation ................................................................................ 46
7.6.4 Voltage and Frequency ........................................................................................ 46
7.6.5 Currents ................................................................................................................ 48
7.7 Parallel Operation............................................................................................................ 50
7.7.1 General ................................................................................................................. 50
7.7.2 Parallel Switching Conditions ............................................................................... 50
7.7.3 Island Parallel Operation ...................................................................................... 51
7.7.4 Operation in Parallel with the Line System .......................................................... 51

8. COMMISSIONING AND STARTING ...................................................................................... 53

8.1 General............................................................................................................................ 53
8.2 Check the Mechanical Installation................................................................................... 53
8.3 Check the Electrical Installation ...................................................................................... 53
8.4 Controller and Protective Equipment............................................................................... 53
8.4.1 General ................................................................................................................. 53
8.4.2 Stator Winding Temperature ................................................................................ 54
8.4.3 Monitoring the Bearing Temperature.................................................................... 54
8.5 First Run .......................................................................................................................... 55
8.5.1 General ................................................................................................................. 55
8.5.2 Before Starting...................................................................................................... 55
8.5.3 Starting ................................................................................................................. 56
8.5.4 Direction of Rotation of the Generator and External Motors ................................ 56
8.5.5 Ground Fault Monitoring....................................................................................... 56
8.6 Operate the Generator for the First Time........................................................................ 56
8.6.1 Monitoring During Operation ................................................................................ 56
8.7 Check the Generator in Operation .................................................................................. 57
8.7.1 Bearings................................................................................................................ 57
8.7.2 Vibration................................................................................................................ 58
8.7.3 Temperature Level ............................................................................................... 58
8.7.4 Heat Exchanger.................................................................................................... 58
8.8 Shut Down the Generator................................................................................................ 58

9. OPERATION........................................................................................................................... 59
9.1 General............................................................................................................................ 59
9.2 Normal Operating Conditions .......................................................................................... 59
9.3 Number of Starts ............................................................................................................. 59
9.4 Monitoring........................................................................................................................ 59

A046V044 (Issue 1) iii

Table of Contents 6-2013

9.4.1 Bearings................................................................................................................ 60
9.4.2 Vibration................................................................................................................ 60
9.4.3 Stator Temperatures............................................................................................. 60
9.4.4 Heat Exchangers .................................................................................................. 60
9.4.5 Slip Ring Units ...................................................................................................... 60
9.4.6 Documentation of Operation................................................................................. 60
9.5 Shutting Down ................................................................................................................. 60
9.6 Anti-condensation Heaters .............................................................................................. 61
9.7 Flashover Pressure Protection ........................................................................................ 61
9.8 Firefighting and Extinguishing Agents ............................................................................. 62
9.8.1 General ................................................................................................................. 62
9.8.2 Extinguishing Agents ............................................................................................ 63
9.8.3 Cleaning After Fire-fighting................................................................................... 64

10. SERVICE AND MAINTENANCE........................................................................................... 65

10.1 Preventive Servicing...................................................................................................... 65
10.2 Safety Precautions ........................................................................................................ 65
10.3 Recommended Servicing Schedule .............................................................................. 66
10.3.1 Generator............................................................................................................ 67
10.3.2 Main Electrical Connections ............................................................................... 68
10.3.3 Stator and Rotor ................................................................................................. 69
10.3.4 Accessories ........................................................................................................ 70
10.3.5 Slip Ring Units .................................................................................................... 70
10.3.6 Lubrication System and Roller Bearings ............................................................ 71
10.3.7 Cooling System .................................................................................................. 72
10.3.8 Safety.................................................................................................................. 73
10.4 Servicing - General Structure ........................................................................................ 73
10.4.1 Strength of Screw Fasteners .............................................................................. 73
10.5 Vibration ........................................................................................................................ 75
10.5.1 Measuring Methods and Operating Conditions .................................................. 76
10.5.2 Definition in Accordance with ISO 10816-3........................................................ 77
10.5.3 Definition in Accordance with ISO 8528-9.......................................................... 77
10.5.4 Warning Values and Shutdown Values .............................................................. 77
10.6 Servicing the Bearings and the Lubrication System...................................................... 78
10.6.1 Roller Bearings ................................................................................................... 78
10.7 Generators with Bearing Insulation ............................................................................... 83
10.7.1 Bearing Insulation on Roller Bearings ................................................................ 83
10.8 Service Windings........................................................................................................... 83
10.8.1 Safety Instructions for Servicing Windings ......................................................... 83
10.8.2 Scheduling the Servicing .................................................................................... 84
10.8.3 Correct Operating Temperature of Windings ..................................................... 84
10.8.4 Insulation Resistance Test ................................................................................. 84
10.8.5 Insulation Resistance Measurement for Ancillary Equipment ............................ 86
10.8.6 The Polarization Index........................................................................................ 86
10.8.7 Servicing the Grounding Brushes....................................................................... 87
10.9 Servicing the Generator Cooling ................................................................................... 88
10.9.1 Servicing Instructions for Generators with Open-circuit Ventilation ................... 88
10.9.2 Service Instructions for Generators with Air Filters ............................................ 89
10.9.3 Servicing Instructions for Generators with Heat Exchangers ............................. 89
10.10 Repairs, Dismantling and Re-assembly ...................................................................... 90

iv A046V044 (Issue 1)
6-2013 Table of Contents

11. FAULT FINDING ................................................................................................................... 91

11.1 Generator, General........................................................................................................ 92
11.2 Lubrication System and Roller Bearings ....................................................................... 93
11.3 Open Cooling System ................................................................................................... 94
11.4 Air-air Cooling System................................................................................................... 95
11.5 Air-water Cooling System.............................................................................................. 96
11.6 Faults on the Brushes .................................................................................................. 97
11.7 Electrical Power, Excitation, Control and Protection ..................................................... 97
11.7.1 Triggering the Protective System ....................................................................... 97
11.7.2 PT-100 Resistive Temperature Sensors ............................................................ 98
11.8 Thermal Performance and Cooling System .................................................................. 98

12. SPARES AND AFTER SALES SERVICE............................................................................. 99

12.1 Customer Service .......................................................................................................... 99
12.1.1 Spare Parts......................................................................................................... 99
12.1.2 Customer Service and Warranty ........................................................................ 99
12.1.3 Important Information ......................................................................................... 99
12.2 Spare Parts for Generators ......................................................................................... 100
12.2.1 General Information on the Spare Parts........................................................... 100
12.2.2 Regular Parts Replacement ............................................................................. 100
12.2.3 Spare Parts Required ....................................................................................... 100

13. END OF LIFE DISPOSAL ................................................................................................... 101

13.1 Disposal....................................................................................................................... 101
13.2 Introduction.................................................................................................................. 101
13.3 Average Material Content............................................................................................ 101
13.4 Recycling Packaging Material ..................................................................................... 102
13.5 Dismantling the Generator .......................................................................................... 102
13.6 Separation of the Different Materials........................................................................... 103
13.6.1 Stator, Bearing Housing, Covers and Fans...................................................... 103
13.6.2 Components with Electrical Insulation.............................................................. 103
13.6.3 Hazardous Waste ............................................................................................. 103
13.6.4 Residual Waste ................................................................................................ 103

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Table of Contents 6-2013

This page is intentionally blank.

vi A046V044 (Issue 1)
1 Foreword
1.1 General
This manual forms part of the items supplied and is an important technical guide to the
intended use of the generator. It represents an essential source of information for the user
and also for managers for the prevention of injuries and damage to the generator.
The generator was manufactured by:
Cummins GeneratorTechnologies GmbH & Co. KG
Bunsenstr. 17
D - 85053 Ingolstadt, Germany
Tel. no.: 0049-(0)841 / 792-0
Fax no.: 0049-(0)841 / 792 250

NOTICE
On the pages that follow the complete name of the company is replaced with the term
"manufacturer".

The generator is the intellectual property of Cummins Generator Technologies. The general
safety regulations, the specific regulations for the place of use and the precautions
described in this document must be followed at all times.

1.2 The Manual

This manual contains guidance and instructions for the installation, servicing and
maintenance of the generator.
Before operating the generator, read this manual and make sure that all personnel who work
on the equipment have access to the manual and all additional documentation supplied with
it. Misuse and failure to follow the instructions, and the use of non-approved parts, may
invalidate the product warranty and lead to potential accidents.
This manual is an essential part of the generator. Make sure that the manual is available to
all users throughout the life of the generator.
The manual is written for skilled electrical and mechanical technicians and engineers, who
have prior knowledge and experience of generating equipment of this type. If in doubt,
please seek expert advice or contact your local Cummins Generator Technologies
subsidiary.

NOTICE
Information in this manual was correct when published. It may be superseded due to our
policy of continuous improvement. Please visit [Link] for
latest documentation.

A046V044 (Issue 1) 1
1. Foreword 6-2013

1.3 Legal
All rights to the generator, the principle of the machine, the related drawings etc. lie with the
manufacturer and subject to the "Gesetz über Urheberrecht und verwandte Schutzrechte"
(UG) (German law on copyright and related property rights) dated 09.09.1965 in the
applicable version.
According to copyright law, competition law and the BGB (German civil code) copying is only
allowed with prior written approval.

2 A046V044 (Issue 1)
2 Safety Precautions
2.1 Safety Information and Notices used in this
manual
Danger, Warning and Caution panels are used in this manual to describe the sources of
hazards, their consequences and how to avoid injury. Notice panels emphasise important or
critical instructions.

DANGER
Danger indicates a hazardous situation which, if not avoided, WILL result in death or serious
injury.

WARNING
Warning indicates a hazardous situation which, if not avoided, COULD result in death or
serious injury.

CAUTION
Caution indicates a hazardous situation which, if not avoided, COULD result in minor or
moderate injury.

NOTICE
Notice refers to a method or practice which can result in product damage, or to draw
attention to additional information or explanations.

2.2 Skill Requirements of Personnel

Service and maintenance procedures must only be carried out by experienced and qualified
engineers, who are familiar with the procedures and the equipment.

2.3 Risk Assessment

A risk assessment has been peformed on this product by Cummins, however a separate risk
assessment must be performed by the user/operating company to establish all personnel-
related risks. All affected users must be trained on the identified risks. Access to the Power
Plant/Generating Set during operation must be restricted to persons who have been trained
on these risks.

2.4 Personal Protective Equipment (PPE)

All persons operating, servicing, maintaining or working in or with a power plant or a
generating set must wear appropriate Personal Protective Equipment (PPE)

A046V044 (Issue 1) 3
2. Safety Precautions 6-2013

Recommended PPE includes:

• Ear and Eye Protection
• Head and face protection
• Safety footwear
• Overalls that protect the lower arms and legs
Ensure that all persons are fully aware of the emergency procedures in case of accidents.

2.5 Grounding
WARNING
High Voltage
Will shock, burn or can cause death.
Work on electrical systems must be done by an electrician or instructed persons under the
management and supervision of an electrician wearing suitable PPE.

Parts of the machine and system on which inspections, servicing and repair work are done
must, if so stipulated, be electrically isolated.
1. Test the electrically isolated parts for electrical isolation using a suitable voltage tester,
then ground and short-circuit and also isolate neighboring live parts.
2. In case of work on high-voltage assemblies, after electrically isolating connect the line
cable to ground and short-circuit the components, e.g. capacitors, using a grounding bar.
The generator is permanently grounded.

2.6 Noise
CAUTION
Generators in operation emit noise.
Exposure to noise can cause hearing damage.
Wear appropriate ear protection at all times. Maximun A-weighted noise emissions may reach
110 dB(A). Contact the supplier for application-specific details.

2.7 Electrical Equipment

DANGER
Hazardous Voltage
Will shock, burn or cause death
All electrical equipment can be dangerous if not operated correctly. Always install, service
and maintain the generator in accordance with this manual.

Work that requires access to electrical conductors must comply with all applicable local and
national electrical safety procedures for the voltages involved and any site specific rules.
Always use genuine branded replacement parts.

4 A046V044 (Issue 1)
6-2013 2. Safety Precautions

2.7.1 Work on Electrical Equipment

DANGER
Hazardous voltage.
Will shock burn or cause death.
The colors of electrical cables and connections comply with the applicable regulations (VDI).
If the operating organization has agreed different colors with the manufacturer, these colors
apply.
Before working on electrical equipment, the entire system must be electrically isolated and
grounded.

DANGER
Hazardous voltage.
Will shock burn or cause death.
Faulty electrical components can be live and as a result life-threatening. Any defects found in
electrical systems, assemblies, equipment must be rectified without delay. If there is an acute
risk until rectified, the system or the assembly must not be used in the defective state.

WARNING
Magnetic field.
Generator has a powerful magnetic field that can interfere with implanted medical devices
such as heart pacemakers.
Do not approach the generator if you have an implanted medical device.

Work on electrical cables is to be done in accordance with local or national electrical safety
regulations applicable for the voltage as well as the safety regulations applicable on the site.
Each generator is built in accordance with the applicable regulations. The electrical control
system is compliant with the VDE regulations, VBG 4 and EN 60204.
• Only use approved protective equipment
• In case of malfunctions in the supply of electrical power, immediately shut down the
unit (exception: if used as an emergency power generator).

2.8 Lock Out/Tag Out

WARNING
Risk of serious injury or death
Generators can retain mechanical and electrical energy
Isolate the generator from all sources of mechanical and electrical energy before starting
service or maintenance work. Adopt a suitable lock-out/tag out process.

2.9 Lifting
WARNING
Improper lifting can cause serious injuries to persons or can cause death.
Do not use the generator lifting points to lift the complete generating set (generator coupled
to motive power source)
The lifting points provided are designed for lifting the generator only.
Do not remove the lifting label attached to one of the lifting points.

A046V044 (Issue 1) 5
2. Safety Precautions 6-2013

2.10 Generator Operating Areas

WARNING
Flying debris
In the event of catastrophic failure, debris may be ejected from the generator air inlet/outlet
and may cause severe injury or death.
Avoid access to these areas while the generator is operating.

Always wear suitable PPE when working in hatched areas or directly in-line with any air
inlet/outlet.
Make sure this consideration is captured in your risk assessment.

2.11 Safety Information Signs

Safety information signs are provided on the equipment to indicate hazards and emphasize
instructions. Become familiar with the signs and the meaning before operating the
equipment. To avoid injury, always take the necessary precautions. Sample signs are shown
in Table 1 on page 6.

TABLE 1. SAFETY SIGN EXAMPLES

Warning Electrical Hazard Rotating Parts Mandatory Protective

(Example: Lifting) Conducter

2.11.1 Hazard Warning Labels

Hazard warning labels are fixed to the generator. If the original labels are missing, damaged
or painted over, replace them with the spare set supplied in a wallet attached to the
generator. Label locations are shown on the back of the label set.

6 A046V044 (Issue 1)
6-2013 2. Safety Precautions

2.12 Oils and Grease

CAUTION
Hazardous Substances
Misuse of oils, grease or other chemical substances can lead to serious injury
When handling oils, greases and other chemical substances pay attention to the safety
regulations, appropriate PPE and environmental regulations that apply.

2.12.1 Solvents and Substances Containing Solvents

NOTICE
Pay attention to the safety regulations on handling solvents. Ask the manufacturer of the
solvent for safety data sheets and first aid measures in case of emergency! The safety data
sheets must be available before using the solvent.

On handling solvents or substances containing solvents always wear protective equipment

such as safety glasses, safety shoes, hard hat, protective gloves and suitable protective
clothing to protect the skin. Always use barrier cream.
Only use solvents in well-ventilated areas. To keep the exposure and hazards as low as
possible, you should:
1. Seal solvent containers immediately after use
2. Ensure that solvent and its vapors are not inhaled.
Solvents are combustible and flammable! A flame is not necessarily required for
ignition, ignition can also be triggered by hot objects at temperatures above the ignition
temperature of the solvent, or by electrical sparks (pay attention to electrostatic
charging).
3. Do not bring organic solvents into contact with oxidizing agents (risk of explosion).

A046V044 (Issue 1) 7
2. Safety Precautions 6-2013

4. Ensure adequate ventilation!

Solvent vapors are heavier than air and can collect on the ground or in hollows. There
is a risk of asphyxiation and explosion!
First aid:
After inhaling larger quantities: copious fresh air, seek medical attention.
After contact with the skin: rinse thoroughly with water.
In case of contact with the eyes: rinse using eye bath and seek medical attention from an
ophthalmologist.
After swallowing: Seek medical attention

2.13 General Guidance

NOTICE
These safety precautions are for general guidance and supplement your own safety
procedures and all applicable laws and standards.

2.13.1 General Safety Instructions

• Only use the generator in correct working condition as well as in the manner intended,
with due consideration for safety and hazards while following the documentation and
the local health and safety regulations.
• Correct any malfunctions without delay that may affect safety or have them rectified by
our service organization.
• Always store this documentation with the generator.
• Regularly check that personal work with due consideration for safety and hazards and
follow the documentation.
• Use appropriate personal protective equipment at all times
• Follow all information on safety and hazards on the generator and maintain in legible
condition.
• On the occurrence of safety-related changes on the generator or in its operating
behavior, immediately shut down the generator and correct malfunction without delay.
• Do not make any changes, additions or modifications to the generator. This statement
also applies to installation and the settings for safety features.
• Do not circumvent or bypass any safety features. Before opening doors or covers for
which the use of a tool is required, the generator must be shut down, electrically
isolated and grounded.
• Spare parts must comply with the technical requirements defined by the manufacturer.
This aspect is only ensured with genuine branded spare parts. On the use of other
spare parts, liability by the manufacturer is excluded.
• Do not make any changes to the program (software) in the programmable control
system. Changes to the program must only be made by appropriately trained
personnel.
• Comply with stipulated intervals or intervals defined in the documentation for regular
inspections and servicing work.
• Use only appropriate tools for undertaking maintenance measures.

8 A046V044 (Issue 1)
6-2013 2. Safety Precautions

• Pay attention to fire alarm and firefighting procedures; pay attention to location and
operation of fire extinguishing systems (see Section 9.8 on page 62).
• Only allow trainees, apprentices or personnel under instruction or personnel
undergoing general training to work on the generator under the constant supervision of
an experienced person.
• Only task trained, experienced persons with the attachment of loads and signaling to
crane drivers. The person providing the signals must be visible for the operator.
• During installation work above head height, climbing aids and working platforms
intended for this purpose with appropriate safety features must be used. Do not use
generator components and attachments as climbing aids! During servicing work at
heights, wear fall arresting equipment.
• Keep all grips, steps, railing, pedestals, platforms, ladders free of debris and dirt.
• The generator electrical equipment is to be checked regularly; loose connections or
burnt, damaged cables must be rectified immediately.
• If work is necessary on electrically live parts, involve a second person who can provide
immediate assistance in case of an emergency. Cordon off working area with a red-
white safety chain and a warning sign. Only use electrically insulated tools. Follow the
local safety regulations, e.g. VDE 0105

[Link] Safety Instructions for Normal Operation

• Refrain from all unsafe forms of working.
• Only operate the generator if all protective devices and safety-related devices, e.g.
detachable protective devices, emergency stop devices, are fitted and functional.
• Inspect daily the generator for externally visible damage and defects. Immediately
report any changes that have occurred (including changes in operating behavior) and
immediately shut down and secure the generator.
• In case of malfunctions, immediately shut down and secure generator. Correct
malfunction without delay.
• Follow the documented procedures for switching on and switching off.
• Before switching on/placing in operation the unit, make sure no-one will be placed at
risk by the starting machine.

[Link] Safety Instructions for Special Tasks

Observe adjustment, servicing and inspection activities and intervals stipulated in the
documentation including information on the replacement of parts/assemblies. Service and
maintenance procedures and tasks should only be carried out by experienced and qualified
engineers, who are familiar with the procedures and equipment.
• Before starting special tasks and maintenance work, inform the operators. Nominate
supervisor.
• During all work related to the operation, the adjustment for production, the conversion
or the adjustment of the generator and its safety-related features as well as inspection,
servicing and repair, pay attention to switching on and switching off procedures as per
the documentation and instructions on maintenance work.
• Mark and cordon off maintenance area as far as necessary.
• When the generator is completely switched off for servicing and repair work, it must be
secured against unintended switching back on using Lock out / Tag out:
• Cordon off switch panel and attach a lock and tag to the main switch.

A046V044 (Issue 1) 9
2. Safety Precautions 6-2013

• Make sure individual parts, as well as larger assemblies, are fastened to lifting
equipment and secured on replacement so that they can cause no harm. Only use
suitable lifting equipment in correct working order with adequate load bearing capacity.
Do not stand or work under suspended loads.
• At the start of servicing / repair, clean generator of dirt and residue of anti-corrosion
agents. Do not use aggressive cleaning agents. Use fluff-free cloths for cleaning.
• After cleaning, check all oil, compressed air lines for leaks, loose connections, chafing
and damage. Correct any defects found immediately.
• If it is necessary to remove safety features during set-up, servicing and repair, the
safety features must be re-fitted and checked immediately on completion of the
servicing and repair work.
• Ensure any materials used are disposed of safely with due consideration for the
environment.

2.13.2 General Guidance for Use

DANGER
Incorrect handling, hazardous voltages, rotating parts and hot surfaces will shock, burn or
cause loss of limbs or death.
Adhere to all safety instructions.

Generators have dangerous, live and rotating parts and hot surfaces. All work in relation to
transport, storage, installation, connection, commissioning, operation and servicing must be
done by authorized, trained specialist staff. National standards, e.g. EN 50 110-1 / DIN VDE
0105 / IEC 60364 are to be followed in the specific case.
It is forbidden to place the unit in operation until the end product is compliant with local
regulations (follow in particular local safety and installation regulations, e.g. EN 60204).
These machines comply with the IEC EN 60034 series of standards. It is forbidden to use
them in potentially explosive atmospheres.
Under no circumstances use a degree of protection ≤ IP23 outdoors or in dusty
environments. Standard Air-cooled models are suitable for ambient temperatures from -
15 °C to +40 °C and altitudes of ≤ 1000 m above sea level. The ambient temperature for
air/water-cooled models must not be less than +5 °C without additional precautions. For
generators with plain bearings, the ambient temperature must not be lower than 0° C. The
oil temperature must be at least 15 °C for the start. (For generators with plain bearings also
see the documentation from the bearing manufacturer). Pay attention to any differing
information on the rating plate. The conditions in the place of operation must match all
agreed information on the rating plate and in the specification.
In cases where there is a contradiction between the content of this manual and the machine
supplied, contact the manufacturer.

10 A046V044 (Issue 1)
3 Safety Directives and Standards
STAMFORD AC generators meet applicable European safety directives, and national and
international standards relevant to generators. The generator must be operated within the
limits specified in the relevant standards and within the parameters on the generator rating
plate.
Marine generators meet the requirements of all the major marine classification societies.

3.1 European Directives: EC Declaration of

Conformity for Incorporation

A046V044 (Issue 1) 11
3. Safety Directives and Standards 6-2013

Each generator supplied in the European Economic Area (EEA) is supplied with an EC
Declaration of Conformity for Incorporation into an electricity generating set. It is the
responsibility of the generating set manufacturer to ensure that the complete generating set
complies with EC Directives and standards.
Our authorized representative in the European Community is Mr Jeffrey Matthews,
Engineering Director, Cummins Generator Technologies Ltd.
All generators meet the following Standards and Directives:
Directives:
• 2004/108/EC EMC Directive
• 2006/95/EC Low Voltage Directive
• 2006/42/EC Machinery Directive
Standards:
• EN 61000-6-1 Electromagnetic Compatibility, Generic Standards - Immunity for
residential, commercial and light-industrial environments
• EN 61000-6-2 Electromagnetic Compatibility, Generic Standards - Immunity for
industrial environments
• EN 61000-6-4 Electromagnetic Compatibility, Generic Standards - Emission standard
for light-industrial environments
• EN ISO 12100-1 Safety of Machinery, Basic concepts, general principles for design -
Basic terminology, methodology
• EN ISO 12100-2 Safety of Machinery, Basic concepts, general principles for design -
Technical principles
• EN ISO 14121-1 Safety of Machinery, Risk assessment - Principles
• EN 60034-1 Rotating electrical machines - Rating and performance
• BS ISO 8528-3 Reciprocating internal combustion engine driven alternating current
generating sets - alternating current generators for generating sets
• BS 5000-3 Rotating electrical machines - Generators to be driven by reciprocating
internal combustion engines - Requirements for resistance to vibration

NOTICE
Once the generator is built into a generating set, it is the responsibility of the generating set
manufacturer to ensure that the generating set complies with the relevant specifications and
standards.

12 A046V044 (Issue 1)
4 Introduction
4.1 Serial Number
Each generator is marked with a unique serial number. This number is marked on the rating
plate on the generator. (See Section 4.2 on page 13)
The serial number is to be stated in any future correspondence related to the generator, as it
is the only information that is used to identify the specific generator.

4.2 Rating Plate

WARNING
Overheating
Can cause catastrophic failure and serious injury from ejected debris.
Always operate the generator within the rated parameters specified on the rating plate .

A rating plate is permanently attached to the generator and must not be removed. The rating
plate provides information on manufacture, identification, electrical and mechanical aspects.

FIGURE 1. RATING PLATE

4.3 Important Remarks

NOTICE
In any areas of contradiction, the specific order-related documents take presidence.

In cases where there is a contradiction between the content of this manual and the
generator supplied, contact the manufacturer.
• The safety measures that are listed in the safety instructions in the manual must be
observed at all times.

A046V044 (Issue 1) 13
4. Introduction 6-2013

Safety in the workplace is dependent on the alertness, care and common sense of all
persons who operate and service the machines. Along with the safety precautions
recommended here, caution is always required in the vicinity of machines: Pay attention to
your safety!

NOTICE
The installation must comply with the instructions and regulations for health and safety. This
statement applies for general safety regulations in the related country, specific agreements
made for the related works, safety instructions included in this manual, and separate safety
instructions supplied with the generator.

4.4 Liability, Warranty and Guarantee

All data and information in this documentation are provided based on our past experience
and knowledge.
The technical information and data described in this documentation relate to the situation at
the date of publication. We reserve the right to make changes in the context of technical
further development without changing this documentation. It is therefore not possible to
derive any claims from the data and descriptions in this documentation.
We accept no liability for damage or interruptions to operation due to operating errors, failure
to follow the instructions, improper servicing or repair. The manufacturer is not liable under
any circumstances for direct, indirect, specific, accidental or consequential damage,
irrespective of its nature, that results from the application of this document; the manufacturer
is also not liable for accidental or consequential damage that results from the use of the
generator.
We specifically highlight that spare parts and accessories not supplied by us must be
approved by the manufacturer of the generator.
Any additional liability for damage resulting from the use of spare parts and accessories that
have not been approved by the manufacturer is excluded by the manufacturer.
Liability covers manufacturing and material defects.
Liability for damage caused by improper storage, incorrect installation or incorrect operation
of the generator is excluded, as are the resulting injuries to the personnel or third party
damage.
The installation and the use of third-party products will degrade the design features of the
electrical machine and impair the safety of people, the system or other property.
Any unauthorized modifications or changes to the generator are not allowed for safety
reasons and exclude liability on the part of the manufacturer for resulting damage. If
attachments/parts provided by the customer are to be installed in or on the generator, this
action must be done in consultation with the manufacturer.
Warranty and liability conditions in the manufacturer's general terms and conditions are not
expanded by the above statements.

NOTICE
Claims cannot be made under the warranty if the operating conditions of the generator have
been changed, changes have been made to the design of the generator or repair work has
been done on the generator without prior written agreement from the manufacturer.

14 A046V044 (Issue 1)
6-2013 4. Introduction

4.5 Intended Use

4.5.1 Operating Conditions
[Link] Vibration Analyses
NOTICE
Serious damage (for example, destruction of the bearings, or cracks in the structure) may be
caused if the vibration allowed in the standard ISO 8528-9 or ISO 10816-3 is exceeded.
Serious damage (for example, destruction of the crankshaft, or destruction of the shaft) may
be caused if the torsional vibration is exceeded (e.g. ABS, LRS|). Ensure that the limits of the
Standards are adhered to.

It is the responsibility of the generating set builder to undertake the calculation,

measurement and evaluation of mechanical vibration in the power generating set (refer to
standards ISO 8528-9 and ISO 10816-3).
It is imperative the rotational vibration calculation is made and checked.

[Link] Purpose
WARNING
Improper use.
Can cause hazards that could result in death or serious injury.
Always a operate in an accordance with the operation instructions.

NOTICE
Consult the manufacturer if you want to use the generator in a different manner to that
described in the order documents.

The generator is designed for onshore or maritime applications as per the order
documentation.

[Link] Impermissible Forms of Operation

Do not operate the generator:
• With operating data different to the data stated on the rating plate.
• With machine features modified by the operating organization.
• Outside the agreed specification

[Link] Permissible Forms of Operation

NOTICE
The generator must only be used for the purpose stated in the order documentation. It must
be operated in accordance with the information in the documentation.

It is only allowed to operate the generator

• In accordance with the procedures described in this documentation and
• If this documentation has been read and understood.
Any other use, as well as use involving hazardous or harmful substances is considered
incorrect use.

A046V044 (Issue 1) 15
4. Introduction 6-2013

NOTICE
Damage caused by operation otherwise than as intended or by incorrect operation is not
covered by the manufacturer's warranty and guarantee obligations. The risk is borne solely
by the user.

We recommend that operating hours, malfunctions, inspections, servicing and repairs are
documented in a log.
If malfunctions or damage cannot be rectified by the operating organization's specialist
personnel, please contact our customer service department.
Address:
Cummins Generator Technologies Germany GmbH
Bunsenstr. 17
85053 Ingolstadt, Germany
Telephone: +49 841 / 792-163
Fax: +49 841 / 792-195

4.6 Documentation
4.6.1 Additional Information
NOTICE
Some customer-specific elements may not be included in this user manual. Additional
documentation can be found in the Appendix. If the information in this manual does not
match the information in the Appendix, the data in the supplementary documentation in the
Appendix applies.

In addition to this manual, each set of documentation is supplied with a dimension drawing
and rotor drawing, an electrical circuit diagram as well as data sheets that state, among
others, the following order-specific information:
1. External dimensions of the generator
2. Generator weight
3. Moment of inertia of the rotor
4. Position of the lifting eyes on the generator
5. Instrumentation and position of additional equipment
6. Requirements on bearing oil and lubricants
7. Main and ancillary connections.

4.6.2 Information Not Included in the Documentation

This user manual does not contain any information on starting, protection or rotational speed
control features as this is not part of our delivery scope.

16 A046V044 (Issue 1)
5 Transportation, Storage and
Corrosion Protection
5.1 Transportation and Packaging
5.1.1 General
The generator is supplied on a transport frame with a transport lock.
The following protective measures are taken in the factory before the delivery of the
generator. If the generator is moved subsequently, the same protective measures are to be
taken:
1. Protect machined surfaces
e.g. the seat for the drive coupling, are protected against corrosion using an anti-
corrosion coating.

5.1.2 General Information for Roller bearings

Ball bearings and roller bearings are lubricated using a lubricant in the factory. The lubricant
is stated on the rating plate.
The first filling of the bearings with lubricant is adequate until the first re-lubrication interval,
provided the generator is not stored.

5.1.3 General Information for Air-Water Coolers

Air-water coolers are drained and the inlets and outlets on the cooler are sealed using
protective caps.

5.1.4 Packaging
Packaging depends on the mode of transport (truck, ship, air freight).
The generator is packed using environmentally-friendly materials (blocks of wood, wooden
crates, plastic sheet) that comply with the IPPC regulations.
• For transport by ship, the generator must be packed for a maritime environment to
protect against splashes of salt water, moisture and vibration damage during loading,
transport and unloading
• For long transport routes, on customer request the generator will be sealed with air-
and dust-tight plastic sheet with desiccant.

5.1.5 During Transport

To avoid damage to the bearings:
• The generator must be transported and moved using a suitable transport frame.
The generator must be transported and unloaded by persons who are familiar with the lifting
equipment and related ancillary equipment. All lifting equipment and tackle must be suitable
for the weight of the generator and must comply with local safety regulations. Secure
transport routes. Lifting fixtures (for example, lifting eyes) must only be used to lift the item to
which they are attached. Always use the lifting features on the base frame to lift the
complete generating set.

A046V044 (Issue 1) 17
5. Transportation, Storage and Corrosion Protection 6-2013

The transport eyes on the generator are only to be used to transport the individual
generator, (not for lifting a complete generating set)

NOTICE
Do not transport using a trolley over uneven surfaces (e.g. rails).)

• The generator must be stored in a vibration-free room.

• The transport markings (pictograms) on the generator packaging must be observed
during transport.
• The generator must only be supported at its feet. Support at other parts is not allowed.
If vibration is to be expected, the generator must be isolated from vibration by placing
suitable vibration elements under the generator feet.
The following information on transport is given in the generator:

FIGURE 2. TRANSPORT INFORMATION

5.1.6 Unpacking Checks/Items supplied

Check that the items supplied correspond to the order specification and the delivery note.
We refer to our terms and conditions of sale and supply.

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5.1.7 Inspection on Arrival

Check the generator and all supplied parts immediately it arrives. Check for evidence of
improper handling. Any transport damage must be photographed and reported to the freight
carrier and the supplier within seven days, so a claim can be made against the transport
insurance.
If the generator is not to be installed immediately do not leave it to stand without further
protection. For further details see Section 5.2 on page 19.

5.1.8 Inspection on Unpacking

Place the generator on a flat surface free of vibration. Ensure there is sufficient access to
the generator and associated components.
Remove the packaging and check that the generator is not damaged. Compare the delivery
with the delivery note enclosed to check that additional items are present. If damage is
suspected or an item is missing, take photographs that clearly show the problem and contact
the freight carrier and the supplier immediately.
Refer to Section 13.4 on page 102 for the correct disposal and recycling of the packaging
material.

5.2 Storage
5.2.1 Storage in a Suitable Room (Less Than 6 Months)
CAUTION
Fire Hazzard
Will burn, cause personal injury or could cause death
Make sure no highly flammable or flammable objects are stored in the vicinity of the anti-
condensation heateror generator packaging.

Suitable conditions are:

• Stable temperature conditions between 10 ºC (50 ºF) and 50 ºC (120 ºF).
• the generator must not exceed 50 °C (120 ºF)
• The ambient air must be clean and free of dust and corrosive gases or salt-laden
aerosols.
• Low atmospheric humidity (below 75%) is required. The generator temperature must be
maintained above the dew point to prevent condensation in the generator.
• If the generator has an anti-condensation heater, the heater must be switched on and
its function checked regularly. The temperature of the generator is also to be
monitored.
• If there is no anti-condensation heater, or it cannot be switched on, use an alternative
heat source to protect the generator against condensation.
• A stable surface free of vibration, protected against knocks. If vibration is expected,
isolate the generator by placing suitable vibration elements under the feet.
• All bare surfaces on the generator are protected on delivery. Check the protection
regularly and:
1. Clean any rust film and other dirt from bare surfaces (ends of shaft, flange, screws
etc.).

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2. Seal the cleaned surfaces using a complete layer of protective lacquer or protective
wax (Tectyl 511M or 846K).
3. If the period of storage/idle exceeds two months, Tectyl 511 or equivalent should be
sprayed through the filler opening into the plain bearing.

5.2.2 Storage in Unsuitable Conditions For Less Than 2

Months
Protect the generator against insects and other small animals. Prevent corrosion, moisture
or the formation of condensation in and on the generator. For temporary outdoor storage
during transport or if suitable store room conditions are not available, the generator must not
be left unprotected in the transport packaging.
1. Fully protect the generator from rain. The cover must be well ventilated to permit the
circulation of air around the generator. If the generator is left in the transport packaging,
ventilation openings must be made in the packaging
2. Place generator with transport frame on blocks so that no moisture can enter the
generator or the transport frame from below. The transport frame and the generator
must be at least 100 mm (4“) off the ground.
3. Make sure the generator is well ventilated.

5.2.3 Storage in a Suitable Room (Longer than 6 Months)

WARNING
Fire Hazard
Will burn, cause personal injury or could cause death
Make sure no highly flammable or flammable objects are stored in the vicinity of the anti-
condensation heater or generator packaging.

Suitable conditions are:

• Stable temperature conditions in the range from 10 ºC (50 ºF) to 50 ºC (120 ºF). The
generator temperature must be kept above the dew point to prevent condensation in
the generator.
• A dust-free, dry environment with low atmospheric humidity (below 75%) is required. If
this requirement cannot be met, the generator is to be stored welded in plastic sheet
with desiccant.
• The ambient air must be clean and free of dust and corrosive gases or salt-laden
aerosols.
• If the anti-condensation heaters are switched on and the temperature of the ambient air
is above 50 ºC, the generator must not heat up to above 50 ºC (120 ºF)
• If the generator has an anti-condensation heater, the heater should be switched
on and its function checked regularly.
• If there is no anti-condensation heater, or it is not possible to place it in operation,
an alternative method is to be used to protect the generator against condensation.
• Make sure the generator sits on a stable surface free of vibration and protected against
knocks. If vibration is to be expected, the generator must be isolated by placing
suitable vibration elements under the generator's feet.

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• All bare surfaces on the generator are protected on delivery. Regularly check the
protection and proceed as follows in case of damage:
1. Clean any rust film and other dirt from bare surfaces (ends of shaft, flange, screws
etc.).
2. Cover cleaned surfaces using protective lacquer or protective wax (Tectyl 511M or
846K).
3. Ensure the layer of lacquer provides a seal!
4. Plain bearings are to be protected against corrosion in accordance with the
information from the plain bearing manufacturer and their protection regularly
checked.

5.3 Protect Against Corrosion

5.3.1 Bare Surfaces
List the corrosion protection measures taken, check their effectiveness with the
manufacturer and check them regularly. Correct any malfunctions and treat corrosion
immediately.
1. Make sure the lacquer or wax seals the part to protect it
2. The ambient air must be clean and free of dust and corrosive gases or salt-laden
aerosols
3. All bare surfaces on the generator are protected with Tectyl or protective lacquer on
delivery. Regularly check the protection and proceed as follows in case of damage:
a. In case of damage, clean any rust film and other dirt from bare surfaces (ends of
shaft, flange, screws etc.).
b. Cover cleaned, damaged surfaces using protective lacquer or protective wax
(Tectyl 511M or 846K).

5.3.2 Roller Bearings

After storage for more than 2 years the bearings and the grease must be replaced before
commissioning the generator.
If the transport lock is re-tightened to a higher torque, the bearing will be damaged. In case
of questions please contact the manufacturer.
To prevent brinelling of roller bearings during storage:
1. Pre-load the bearing using the transport lock.
2. Remove the transport lock and Turn the rotor monthly so that the position of the rolling
elements changes. The rotor must rotate at least 420°.
3. Fill the entire bearing chamber with grease.

5.3.3 Air-air Cooler

Check the effectiveness of the corrosion protection measures annually. Or more frequently
in particularly unfavorable ambient conditions. Renew the corrosion protection measures if
necessary.
1. Clean the entire cooling path by blowing out with dry air.

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5.3.4 Air-water Cooler

Check the effectiveness of the corrosion protection measures annually. Or more frequently
in particularly unfavorable ambient conditions. Renew the corrosion protection measures as
necessary.
1. Drain the existing cooling water.
2. Clean the cooling water pipes and flush using clean, clear water.
3. Dry the cooler with warm, pre-dried air.

5.3.5 Customer Connection Openings

Clean the Cooler and pipes and blow through warm, dry air to dry them. Seal the Openings
through which cables are not yet connected to terminal boxes or flanges that are not yet
connected to pipes.

5.4 Remove Corrosion Protection

NOTICE
Do not remove the anti-corrosion coatings using emery paper.

Before operating a corrosion-protected generator, remove the measures taken and logged
for storage and establish the state required to commission the generator.
• Remove the anti-corrosion coatings using white spirit or a similar oil-based solvent.

5.4.1 Roller Bearings

Check which measures were applied for protection against corrosion, remove as
appropriate.
The amount of grease in the bearings for long-term storage must be reduced to the specified
amount for operating the generator. Open the bearing chamber, remove the excess grease
and re-seal the bearing chamber. In case of questions related to the amount of grease,
please contact the manufacturer with the machine number.

NOTICE
An excessive amount of grease or old grease in the bearings during operation will result in
serious bearing damage! Pay regard to the storage time and the grease amount.

Check the amount of grease in the attachments. If necessary contact the manufacturer for
information on the first filling.

5.4.2 Cooler
Follow the operation and maintenance instructions supplied by the cooler manufacturer.

[Link] Air-water Cooler

Fill and operate the water circuit according to the operating and maintenance instructions
from the cooler manufacturer. You will find these instructions in the Appendix.

[Link] Air-air Cooler

Operate the air-air cooler according to the operating and maintenance instructions from the
cooler manufacturer. You will find these instructions in the Appendix.

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5.4.3 Condensed Water Drain

DANGER
Harzardous Voltage
Will shock, burn or cause death.
In case of condensed water, do not operate the generator without the repairs and inspections
described in Chapter 10 on page 65.

Check whether condensed water has formed in the generator. If there is condensed water
present, open the drain plug at the lowest point on the generator and close again after
draining the condensed water.

5.5 Oil Drain Points

TABLE 2. NON DRIVE END

No Description
1 Oil Ring Sight Glass
2 Oil Sight Glass
3 Oil Drain

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5. Transportation, Storage and Corrosion Protection 6-2013

TABLE 3. DRIVE END

No Description
1 Oil Ring Sight Glass
2 Oil Sight Glass
3 Oil Drain

24 A046V044 (Issue 1)
6 Installation and Alignment
6.1 General
DANGER
Hazardous voltage and rotating parts.
Will shock, burn, or cause loss of limbs or death.
Prevent unintentional operation of the generator and accidental damage caused when work is
done nearby.

Follow general and local health and safety instructions during installation.
Good planning and comprehensive preparations before installation are necessary for
malfunction-free, reliable and safe operation of the generator
Follow the standards for connections and use of electrical equipment, in particular national
standards, for the installation of the equipment (e.g. see standard IEC 60079-14 or EN
60204).
When welding, do not use generator as (earth) ground.

6.2 Preparation of the Generator

Prepare the generator as follows before installation:
1. Measure the insulation resistance of the windings as described in Section 7.4.4 on
page 39.
2. If necessary, remove the transport lock. Keep it in a safe place for future use. To
prevent bearing damage the transport lock must always be attached to the generator if
the generator is moved, or placed in storage. See Section 5.1.1 on page 17.
3. Remove the anti-corrosion coating from the end of the rotor shaft and the generator feet
using white spirit or a similar oil-based solvent.

6.2.1 Generators with Roller Bearings

Generators with two roller bearings must be connected to the prime mover using elastic
couplings to ensure continuous free axial movement between the coupling halves due to
thermal expansion of the generator shaft without bearing damage.
The non-drive end bearing is always fixed. The axial thermal expansion of the rotor is
calculated as described in Section 6.4.3 on page 31. If in doubt, contact the manufacturer.
• Make sure the grease is compliant with the specification on the rating plate and make
sure the bearing is filled with the correct amount of grease. See Section 5.4 on page
22.

NOTICE
An excessive amount of grease or old grease in the bearings during operation will
result in serious bearing damage. Pay regard to the storage time and the grease
amount.

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6.2.2 Recommendations for Coupling Assembly

[Link] Balance Condition of the Rotor
Balance the rotor coupling half corresponding to the rotor balancing. A standard rotor is
dynamically balanced using half keys. The type of balancing is marked on the end of the
rotor shaft:
H = Half key
F = Whole key
N = No key

[Link] Assembly
WARNING
Rotating Parts.
Will cause severe injury. The coupling is to be protected with a guard. There is a hazard in
operation due to rotating parts.
In operation, be careful of rotating parts.

WARNING
Hot parts.
Cause serious burns.
Prevent skin contact with hot parts using PPE.

1. Follow the general instructions from the coupling manufacturer

2. The coupling can be heavy. Use suitable lifting equipment
3. Clean the anti-corrosion coating from the coupling seat on the shaft and compare the
dimensions of the end of the shaft and the coupling with the outline drawing provided.
4. Make sure that the key slots in the coupling and the shaft are clean, free of burrs and
undamaged.
5. Smear the shaft and the hub bore with a thin layer of resin-free oil to ease the assembly
of the coupling half.
Never smear mating surfaces with molybdenum disulfide (MoS2) or similar products.
6. On mounting a feature on the bores and threads in the shaft, consult with the
manufacturer.
7. If it is necessary to heat the coupling to ease fitting, follow the temperature information
from the coupling manufacturer.
To prevent damage to the bearings, do not put additional forces on the bearings while
assembling the coupling half.

6.3 Mounting Design

6.3.1 General
The mounting design and construction is the responsibility of the customer or a third-party.
The mounting design must ensure safe operating conditions and good access for servicing
and monitoring. Cooling airflow must be unhindered to and from the generator. Nearby
machines or equipment must not heat the cooling air for the generator or its attachments,
such as the bearings.

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The mounting must be stable, stiff and free of external vibration. Check for resonance; the
natural frequency of the mounting with mounted generator must not lie within ±20% of the
operating frequency.
The mounting must be designed to support the weight of the generator and include air,
water, oil and cable ducts. The dimensions of the connection features must match the
corresponding dimensions on the outline drawing provided.
The mounting must be designed to accomodate all the manufacturing tolerances.

6.3.2 Mounting Forces

The mounting and the fastening screws must withstand mechanical moments that occur
during generator starting, operation and transient events. Refer to the technical data sheet
for the loads.
The calculation of the mounting forces is not included in the items supplied, for this reason
the customer or a third-party is responsible for this task. If necessary, calculation can be
agreed in the project planning phase.

6.3.3 Mounting on Ships

[Link] General Requirements
The classification and design requirements of the certification authority apply to the design
and implementation of mountings on ships.

[Link] Calculations
Check and calculate during the project phase
1. The natural frequency of vibration in the overall system in 6 degrees of freedom.
2. Calculate the static displacements in x, y and z directions on all elastic components.
Take into account all loads effective at nominal power output due to the inherent weight
of the motor, the motor nominal torque (or output torque for flange-mounted
gearboxes), and ship pitch and roll motion.
3. Compare the displacement values calculated with the values allowed for the electrical
components.
4. Calculate the forced damped vibration.
The result must conform to the specifications for the ship classification and be agreed with
the manufacturer of the component

[Link] Fastening to the Mounting

Only screw joints must be used for fastening the drive systems to the ship-borne mounting.
To keep settling to a minimum, the number of joints in the screw joints is to be limited to a
minimum.
The contact surfaces for screw heads and nuts must be flat and machined parallel.
Do not tack weld generator mounting screws and nuts.
The screw joint must be designed for the maximum possible load that can occur.
The required pre-load on the mounting screws is to be defined in agreement with the
manufacturer of the prime mover or the manufacturer of the related system component.
The preferred fastener type is a cap screw, installed so that the screw pre-load can be
checked at any time.

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[Link] Requirements
Follow the manufacturer's installation regulations during the mechanical mounting of the
individual components on the foundation.
Design of the mounting must be agreed with the certification authority.
Make sure the assembly and inspection openings on the drive systems provided for
maintenance measures remain accessible.
Final fastening must be done after alignment done. Consider the operation-related thermal
expansion and the dynamic behavior of the system components (coupling, gearbox etc.)
during alignment.
Make sure that the alignment of the individual system components to each other does not
change during mechanical work on the mounting.
All welding work in the area of the mounting must be completed before mounting the
generator.
During the design of an elastic mounting, consider the aging and natural wear of the
mounting elements. Check and log the settling rates at intervals specified by the
manufacturer. Replace the elastic mounting when the maximum allowed amount of settling
occurs.

6.3.4 Installation on Concrete Foundations

[Link] Items Supplied
The installation shims, fastening screws and mounting pads or bed plates are not included in
the normal items supplied with the generator. These can be supplied to special order.

[Link] Calculations
Check and calculate during the design phase
1. The natural frequency of vibration for the overall system in 6 degrees of freedom.
2. Calculate the forced damped vibration.
3. Calculate the mounting forces and screw joints
The results must conform to the specifications and be agreed with the manufacturer of the
related system component.

[Link] Prepare the Foundation and the Holes in the Foundation

Mounting pads in accordance with DIN 799 or bed plates can be used to anchor the
generator in a concrete foundation.
Take into account the following points during the preparation of the foundation:
• Compare the position of the holes in the foundation and the height of the foundation
with the related dimensions on the outline drawing.

[Link] Prepare the Mounting Pads or the Bed Plates

If required, shims and mounting pads are supplied as separate parts for fitting on site.
To ensure the firm seating of the mounting pads in the concrete, they must be unpainted
and free of dirt and dust.
1. Lift the generator with a crane to assemble the mounting pads or bed plates to the
generator.
2. Clean the parts that are cast in the concrete.

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3. Clean parts protected with an anti-corrosion coating using solvent.

4. Only screw greased alignment screws into the mounting pads or bed plates.
Make sure that clearances and fasteners are free of concrete.

[Link] Install the Generator

Lift the generator carefully and, together with the coupling half and bed plates or mounting
pads, fit it into the holes that have been made on the existing foundation. The coupling is
fitted in accordance with the specifications from the coupling manufacturer.

[Link] Position the Mounting Pads or the Bed Plates

The bed plates or mounting pads must either be positioned together with the generator or
separately, so that the generator can be aligned afterwards within the range of its
adjustment features.

[Link] Cementing
NOTICE
Cracks in the concrete or poor fastening to the concrete foundation can loosen the generator.
Fill the holes in the foundation completely and avoid cavities.
Cementing the generator in the foundation is a very important part of the installation. Follow
the instructions of the concrete manufacturer.
Use high-quality concrete that is not subject to shrinkage to prevent problems during
cementing.

[Link] Final Installation and Inspection

1. After the concrete has hardened, re-tighten the foundation bolts.
2. Lock the nuts using approved locking generators (e.g. DIN).
3. Tighten the fastening screws.
4. Check and correct the alignment to ensure the generator runs with the permissible
vibration.
5. Complete the installation by fitting dowel pins.

6.3.5 Installation on Steel Foundation

[Link] Items Supplied
Installation shims or fastening screws are not included in the normal items supplied. These
can be supplied to special order.

[Link] Inspect the foundation

Before lowering the generator onto the foundation:
1. Clean the foundation thoroughly
2. Check that the foundation is flat and level (parallel error maximum 0.1 mm (4.0 mil))
3. Check that the foundation is free of external vibration.

[Link] Install the Generator

Lift the generator carefully and, together with the coupling half, fit it on the existing
foundation. The coupling is fitted according to specifications from the coupling manufacturer.

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[Link] Coupling Cover and Enclosures

Before fitting enclosures and operating the generator but after installing and aligning the
generator, make sure that there are no tools or foreign bodies left inside the generator or the
enclosures

WARNING
Rotating parts.
Can cause loss of limbs or death.
The coupling must be protected with a guard. In operation, be careful of rotating parts.

Keep the alignment and installation equipment together with the transport lock for future use

6.4 Align the Prime Mover and Generator

6.4.1 General
To ensure a long, satisfactory service life for both the prime mover and the generator, both
must be correctly aligned. This means that the radial and angular offset between the two
shafts on the machines must be minimized.
Be sure to complete an alignment report. Claims relating to damage can only be considered
if an alignment report is available. Before starting the alignment work, remove all transport
locks and rotor fastenings. Undertake alignment with great care, as alignment errors will
result in bearing and shaft damage. Even small alignment errors will result in uneven running
of the machines and bearing damage.

6.4.2 Theory of Alignment

The accuracy of alignment is related to the tools used for the alignment (dial gauges, laser
measuring instrument).
• A laser measuring instrument is most accurate.
One of the two machines to be coupled is defined as the reference point. On power
generator sets this reference point is generally the prime mover.
• Fine alignment is dependent on the design of the machine, as follows:

TABLE 4. ALIGNMENT OFFSET AND

SPEED

Nominal speed: Maximum radial

offset:
1800 revs/min 0.05 mm
1500 revs/min 0.06 mm
1000 revs/min 0.08 mm
750 revs/min 0.09 mm
600 revs/min 0.11 mm
375 revs/min 0.15 mm

General figure for the angular offset: ≤ 0.05 mm / 100 mm coupling diameter
General figure for the coupling distance: ≥ 3 mm

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FIGURE 3. RADIAL OFFSET

FIGURE 4. ANGULAR OFFSET

FIGURE 5. AXIAL OFFSET

On alignment with the machines cold it is to be taken into consideration that generator,
gearbox and prime mover may have different thermal expansion. This situation will result in
different height changes on the parts when warm.

6.4.3 Compensate for Thermal Expansion

Operating temperatures have a significant effect on alignment and must be taken into
account. The temperature of the generator under operating conditions is higher than during
installation. The center of the shaft will be higher during operation, i.e. further away from the
base than at rest due to thermal expansion.
Thermally-compensated alignment may be necessary depending on the operating
temperature of the generator, the type of coupling, the distance between the two machines
etc.

[Link] Vertical Thermal Expansion

Vertical thermal expansion is always to be taken into account.
The thermal expansion of the generator can be calculated approximately using the distance
between the base and the center of the shaft:
∆H = α × ∆T × H
Where
∆H= Thermal expansion [mm]
α= 10 × 10-6 K-1
∆T= Temperature difference between alignment temperature and operating temperature to
be expected [°K]
H= Shaft height [mm] (see outline drawing)

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Take into account the thermal expansion of the generator in relation to the prime mover to
determine the overall thermal expansion.

[Link] Axial Thermal Expansion

Axial thermal expansion is always to be taken into account.
The calculation is made from the fixed bearing on the generator to the end of the shaft on
the drive side (see rotor drawing in the Appendix).
The fixed bearing is on the B end (NDE - non-drive end) of the generator for roller bearings
and on the A end (DE - drive end) of the generator for plain bearings. In case of queries
related to the fixed bearing and the thermal expansion please contact the manufacturer.
The thermal expansion can be calculated approximately using the distance between the
fixed bearing and the other end of the rotor shaft:
∆L = α × ∆T × L
Where
∆L= Thermal expansion [mm]
α=10 × 10-6 K-1
∆T= Temperature difference between alignment temperature and operating temperature to
be expected [°K]
L= Distance from the fixed bearing to the AE of the shaft [mm]
Make sure that continuous free axial movement is possible between the coupling halves
(except fixed couplings) to permit axial thermal expansion of the generator shaft and prevent
bearing damage.

6.4.4 Assemble the Coupling Halves

The coupling halves are assembled in accordance with the requirements from the coupling
manufacturer. The coupling halves on the prime mover and generator are placed together
loosely so that they can move freely in relation to each other during the alignment.

[Link] Run-out on the Coupling Halves

NOTICE
Do not turn generator rotor using the fan. The fan will not withstand such forces and will be
damaged.

The alignment process starts with the measurement of the run-out on the coupling halves.
This measurement provides an indication of any inaccuracy on the shaft and/or the coupling
halves.
The run-out on the coupling halves is measured in relation to the generator bearing housing.
Fit the dial gauges as shown in Figure 6 on page 33. Rotate the rotor shaft with a simple
lever. Check the run-out of the coupling half on the prime mover in relation to the bearing
housing.
Fill plain bearings with oil before rotating. The permissible run-out error is less than 0.02 mm
(0.8 mil).

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FIGURE 6. MEASUREMENT OF THE RUN-OUT ON THE COUPLING HALF

The alignment must be performed with great care. Otherwise, the prime mover and the
generator can be seriously damaged by heavy vibration. Measure alignment performed
according to instructions from the coupling manufacturer. Parallel, angular and axial
alignment of the generator is required.

6.4.5 Coarse Alignment

For ease of alignment and the fitting of shims, alignment screws are fitted to the generator
base.
The generator stands on the alignment screws. Please note that the generator must stand
on all feet (screws) in a plane with a maximum of 0.1 mm (4.0 mil) parallel error. If this is not
the case, the generator will twist or distort, which will result in bearing damage and other
damage.
• Make sure the generator is leveled vertically, horizontally and axially. Make the
necessary adjustments by, e.g., placing alignment elements or shims under the feet.

6.4.6 Final Alignment

Plain bearings are to be filled with oil before rotating.

NOTICE
Do not turn generator rotor using the fan. The fan will not withstand such forces and will be
damaged.

The generator is aligned as follows:

1. The generator must stand on its alignment screws.
2. Turn the rotor with a simple lever and check the axial play.
3. Fit the alignment equipment.
4. If dial gauges are used, their scale must be adjusted so that about half the scale is
available in both directions. Check the strength of the dial gauge holder to prevent
possible bending, see Figure 7 on page 34.

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FIGURE 7. ALIGNMENT USING DIAL GAUGES - 1: RADIAL ALIGNMENT, 2: ANGULAR

ALIGNMENT
5. Measure and note the values for radial, angular and axial offset in four different
positions: top, bottom, right and left, i.e. every 90°, while the coupled shafts are rotated
at the same time. Record the values.
6. Align the generator vertically by turning the alignment screws or by lifting using
hydraulic lifters. For ease of radial alignment, alignment screws are fitted to the
generator feet. The expansion of the base frame due to thermal action can affect the
accuracy of the alignment (see Section 6.4.3 on page 31).
7. If no alignment elements (e.g. Vibracon) are used, please proceed as follows:
a. Measure the distance between the underside of the generator feet and the base
frame and fabricate appropriate solid blocks, or have the necessary quantity of
shims available.
b. Place the solid blocks or shims under the generator feet. Loosen the alignment
screws and tighten the fastening screws.
8. Check alignment again and correct, as required.
9. Re-tighten the nuts and secure them using approved (DIN) locking elements.
10. Fasten the generator feet using dowel pins to simplify the possible future re-installation
of the generator; see Section 6.5 on page 36

[Link] Permissible Offset

Definitive alignment tolerances cannot be stated, as there are too many factors that play a
role. Excessively large tolerances will cause vibration and may result in bearing damage or
other damage. For this reason it is recommended to keep the tolerances as low as possible.
The tolerances stated by the coupling manufacturer only apply to the coupling, not to the
alignment of the prime mover and load machine. They can only be used as general figures
for the alignment if they are lower than the maximum values stated in Section 6.4.2 on
page 30.

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[Link] Align a Generator with Axial Play

In case of generators that permit axial play in the fixed bearing, an adjustment indicator is
fitted and there is a marking on the shaft that indicates the operating center point. The rotor
is operated in the correct position if the pointer is aligned with the groove on the shaft. This
so-called operating center point does not necessarily match the magnetic center point of the
generator. The fan and magnetic forces can pull the rotor out of the generator's geometric
center point. Pay attention to any adjustment indicator fitted and its position.

[Link] Align a Two Bearing Generator

During the alignment of two-bearing generators the following errors can occur:
1. Radial offset
2. Angular offset
3. Axial offset
If aligning when the generating set is cold, consider that the height of generator, gearbox
and prime mover is different when warm due to differences in thermal expansion.
• Align the coupling (minimum axial offset) according to the instructions from the coupling
manufacturer. During this process consider the linear expansion of the shafts when
reaching the operating temperature.
• Use suitable alignment aids, e.g. dial gauges or a laser instrument, for the fine radial
alignment of the generator.

[Link] Align a Single Bearing Generator

The objective of the alignment on one-bearing generators is to keep the air gap between the
rotor and stator equal all round so that the rotor is exactly aligned radially.
For the axial alignment the distances on the B end (non-drive end) must be met.
Refer to the illustration in the Appendix for the dimension that defines the axial center
position of the rotor.
To align the generator, proceed as follows:
1. Remove the radial transport lock.
2. Roughly align the generator on the base frame or the bed plates. (See Section 6.5 on
page 36)
3. Couple the prime mover and generator without using force.
Pay attention to the following points:
• Crankshaft clearance on the combustion engine.
• Air gap between rotor and stator.
• Axial dimension as per sketch in the Appendix.
• Check the radial alignment accuracy by measuring the distance between the shaft and
the machined inside diameter of the bearing plate.

[Link] Alignment of Generators with Flange-mounted Gearbox

Follow the documentation from the gearbox supplier to align a generator with a flange-
mounted gearbox done.

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6.5 Fit the Dowel Pins

The generator does not have any bores for dowel pins in its feet. Cummins recommends
fitting tapered pins (DIN 258) to maintain exact alignment and to permit easier re-installation
of the generator if removed.

6.6 Measures for Delayed Commissioning

External vibration will damage all types of bearings and shorten the service life of the
bearings.
If the generator is not operated for an extended period after installation, follow the measures
described in Section 5.2 on page 19. In addition, rotate the shaft 10 turns at least every 3
months and the fill the self-lubricating bearings with oil. If the generator is subject to external
vibration, the generator must be un-coupled.

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Connections
7.1 General
Do not drill additional holes and threads. The generator will be damaged.
Mechanical and electrical connections are made after installation and alignment. Mechanical
connections can include the connection of air ducts, water pipes and/or an oil supply system.
Electrical connections include the connection of line cables and additional cables, ground
cables and optionally external fan motors.

7.2 Mechanical Connections

7.2.1 Cooling Air Connections
[Link] Connect Air Ducts
Clean the air ducts thoroughly before you connect them to the generator and make sure
there are no obstructions in the ducts. Seal the joints using suitable seals. After connecting
the air ducts, make sure that there are no leaks.
Generators that are designed for the possible connection of air ducts have connection
flanges shown in the outline drawing.

[Link] Connect a Cooler to the Generator

Generators that are equipped with a heat exchanger for their cooling have a cooling air seal
on the heat exchanger.
If the heat exchanger or parts of the cooling system are supplied separately, they must be
installed on site as follows:
1. Lift the cooler or the individual parts only by the lifting eyes using suitable lifting
equipment.
2. Make sure all connection components are free of dust and dirt.
3. Refer to the outline drawing in the Appendix for the correct installation positions.
4. Lift the cooler parts at the point provided and fasten them using the hardware provided.
5. Make sure all seals are fitted correctly.

[Link] Connect an External Fan Motor

The external fan motor is generally an asynchronous three-phase motor. The terminal box
for the fan motor is on the motor housing. The rating plate on the external fan motor
indicates the voltage and frequency to be used. The direction of rotation of the fan is marked
with an arrow.

NOTICE
Check the direction of rotation of the external fan motor (fan) visually before you start the
generator. If the fan motor runs in the wrong direction, its phase sequence must be changed.

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7.2.2 Connect Cooling Water

[Link] Air-water Cooler
Generators that are equipped with an air-water heat exchanger have connection flanges.
Connect the flanges and seal the joints using suitable seals. Refer to the outline drawing in
the Appendix for the size of the connection flanges.
• Ensure that the water circuit has no leaks, before starting the generator.

7.3 Connect Vibration Sensors

7.3.1 Roller Bearings
Standard Generators with roller bearings are equipped with bores for the connection of SPM
vibration sensors.

7.4 Electrical Installation

7.4.1 General Information
DANGER
Hazardous voltage.
Will shock burn or cause death.
Before installation make sure that the supply cables are disconnected from the power system
and that the cables are grounded.

The safety information in Chapter 2 must be observed at all times

Plan the electrical installation thoroughly before implementation. Read the Circuit diagrams
supplied with the generator thoroughly before starting the installation work. It is important
that the line voltage and frequency for all electrical equipment correspond to the values
stated on the related rating plate or in the circuit diagram.
The line voltage and the frequency must lie within the limits stated in the related standard.
The data must correspond to the data on the rating plate and be connected according to the
circuit diagram.

7.4.2 Safety
Electrical work must be done by appropriately qualified specialist personnel. The following
safety instructions must be followed:
1. Switch off all units including ancillary equipment
2. Provide securing features to prevent unintentional switching back on
3. Make sure all parts are disconnected from their related power supply
4. Short all parts to protective ground and short-circuit the switching circuits
5. Cover all live parts and cordon off the surrounding area
6. If the secondary circuit is expanded with a current transformer, make sure that an open
circuit does not occur during use.

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7.4.3 Moisture
The ability of air to absorb water is temperature-dependent. If the air temperature drops
below the saturation point, condensation may form on the winding insulation, as a result the
electrical resistance will drop. Further protective measures are necessary in a humid
operating environment!

7.4.4 Insulation Resistance

Measure the insulation resistance of generators that have been stored or have not been
operated for an extended period, before initial commissioning.
1. Ground all parts to which the measuring voltage is not applied.
2. Before measuring the insulation resistance of the winding, disconnect all connections
(primary connection, measuring connection, connections to the control system, safety
circuit and interference suppression circuit).
3. During insulation measurements, measuring equipment and measuring wires must be
disconnected.
4. Before commissioning, measure the insulation resistance on the stator winding from
phase to phase and from phase to ground, and also measure the rotor winding to
ground.
5. The measurement is to be done using 1 kV DC on low-voltage generators (< 1 kV) or
using 5 kV on high-voltage generators (≥ 1 kV).
Due to the capacitive charging of the winding, the measuring instrument only indicates the
correct value for the insulation resistance after 60 seconds.
• The winding section is to be grounded immediately after switching off the measuring
voltage
For excessively low insulation values:
1. Check insulation on the terminals for soiling and moisture.
2. Clean and dry terminals as necessary.
3. Repeat the insulation resistance measurements.
4. Damp windings can result in leakage currents, flashover or breakdowns. Damp
windings must be dried.
For low-voltage generators with nominal voltage < 1 kV, as well as in the rotor winding, the
insulation resistance must be 5 MΩ at 25 °C.
For medium and high-voltage generators with nominal voltage ≥ 1 kV the necessary
insulation resistance in MΩ is to be calculated using the equation
R ≥ 3 + 2 x UN UN
Where UN is the nominal voltage of the generator in kV.
• As the windings are connected at the pillars or bars, these must be checked during the
insulation test and measurement.

NOTICE
On all secondary connections and measuring connections, the maximum test voltage is 500
V DC. The insulation resistance must not be less than 5 MΩ

• The secondary connections, such as measuring connections to transducers, all

connections to the control system, safety circuits and interference suppression circuits
must be checked separately.

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• Each of these connections must be checked separately on the terminal strip. During
this process the insulation resistance of the terminal strip must be measured.
If the insulation resistance on new, cleaned or repaired windings is less than 5 MΩ, the
winding must be dried.

7.4.5 Main Terminal Box

The inside of the main terminal box must be free of dirt, moisture and foreign bodies. The
box itself, the cable glands and unused cable entries must be sealed.
The main terminal box is attached to the top or side of the generator. In the standard version
three of the four terminals are used for the power outputs U1, V1 and W1; the fourth is used
for forming the star point for the three ends of the windings U2, V2 and W2. In case of
factory-fitted current transformers, a copper bar forms the fourth terminal (N).
A connection feature for low-voltage connections such as a control system, temperature
sensor, heating or similar item is, depending on the size of the generator, either on the
bearing plate on the B end or in a separate auxiliary terminal box on the stator housing.

7.4.6 Auxiliary Terminal Boxes

Auxiliary terminal boxes are attached to the generator to suit the additional equipment and
customer needs; See the positions on the outline drawing.
The auxiliary terminal boxes are equipped with terminal blocks and cable glands. As
standard, the maximum cross-section of the conductors must not exceed 1.5 mm²
(0.0024sq. in.) and the voltage to 500 V. Existing cable glands are suitable for cables with a
diameter of 10-16 mm (0.4”-0.6”).

7.4.7 Isolation Distances for the Primary Line Connections

The connections for the primary line cables must be designed in accordance with the
operating conditions.
To ensure lasting, trouble-free operation, the isolation distances and the creep path
distances must be adequately dimensioned. The minimum isolation distances and creep
path distances must comply or exceed the requirements defined by:
• Local regulations
• Standards
• Classification regulations
• Hazard zone classification

7.4.8 Primary Line Cables

DANGER
Hazardous voltage.
Will shock, burn or cause death.
Fasten the primary line cable connections correctly to ensure reliable operation. Prevent
vibration on the primary line cable connections. If necessary, use additional supports
approved by the manufacturer. Provide the manufacturer with the related information during
project planning.

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DANGER
Hazardous voltage.
Will shock, burn or cause death.
Before installation of the generator, make sure that the power cables are disconnected from
the supply system and that the cables are connected to the protective ground.

The dimensions of the power cables must be designed for the rated current and comply with
local standards. The cable terminating fittings must be of a suitable type and be of the
correct size. Check the connections on all equipment.
Standard stator terminals are marked in accordance with IEC 60034-8 using the letters U, V
and W. The neutral terminal is marked with N. Insulation stripping, connecting and insulating
high-voltage cables must be done in accordance with the instructions from the cable
manufacturer.
Fasten the cables so that the bus bar in the terminal box is not placed under mechanical
load.
Compare the phase sequence with the circuit diagram and rating plate.
• Seal unused cable glands in the terminal box and generator against the ingress of dust
and moisture so they cannot loosen.
• Re-tighten all contact screws and nuts to the specified torque.
• If sudden loads or generator vibration are to be expected, fasten cables using cable
clips or cable racks.
• Make sure there is enough play at elastically mounted equipment.

FIGURE 8. VIBRATION DAMPERS ON BASE FRAME. ENSURE FREE CABLE LENGTH.

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FIGURE 9. VIBRATION DAMPERS ON FOUNDATION. ENSURE FREE CABLE LENGTH.

[Link] Recommendation for Power Cable Connection to the Customer's

System
• Connect the cables in accordance with DIN 46200
• Use approved screw locking elements for cable fastenings and only fit these to the
connection on one side of the clamped conductor
The other side of the clamped conductor is reserved for carrying the electrical power. Only
use washers or locking plates made of copper-zinc alloys (brass). Materials with equivalent
electrical and mechanical properties are also allowed.

[Link] Recommendation for Bus Bar Connection to the Customer's

System
• Bus bar connection in accordance with DIN 46200
• Use approved screw locking elements for the bus fastenings and only fit these to the
connection on one side of the clamped conductor. The other side of the clamped
conductor is reserved for carrying the electrical power, for this reason it is only allowed
to use washers or locking plates made of copper-zinc alloys (brass).
• Materials with equivalent electrical and mechanical properties are also allowed.
Fasten the bus bar connections to the customer's system correctly to ensure reliable
operation. Prevent vibration on the bars. If necessary, use additional supports and
decoupling approved by the manufacturer. Provide the manufacturer with the related
information during project planning.

[Link] Transducer Installation

Do not operate the generator until any required transducer is installed.

[Link] Interference Suppression

The generators comply with the requirements of interference suppression class "N" in
accordance with VDE 0875.
For good interference suppression, pay attention to correct grounding with an appropriate
protective ground conductor with the stipulated minimum conductor length.

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[Link] Connection of Additional Equipment and Instruments

Mark the terminals of additional equipment if they are live while the generator itself is
switched off.
Connect the instruments and the additional equipment as per the circuit diagram.
Refer to the circuit diagram supplied with the generator before connecting the cables. The
connection and function of the additional equipment must be checked before commissioning.

[Link].1 Grounding Connections

Connect grounding according to local regulations before the generator is connected to the
supply voltage.
The generator and related equipment must be connected to protective ground. The
connections to protective ground must be able to protect the generator against damaging or
dangerous electrical potentials (voltage).
The manufacturer's liability does not cover damage as a consequence of incorrect grounding
or incorrect cabling in the customer's installation.

7.5 Criteria That Affect the Output Power

7.5.1 Design Criteria
The following criteria are used during design:
• Coolant temperature
• Installation altitude
• Degree of protection
• Type of cooling
• Power factor
• Ship classification

7.5.2 Effect of Coolant Temperature

Do not increase the output power above the rated output power specified in the order.
The limit temperature of the winding is definitive.
• If the cooling air temperature drops, the output power increases.
• If the cooling air temperature increases, the output power drops.
The parameters for the specific generator selected, e.g. reactances, apply in general for the
rated output power defined (SN).

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FIGURE 10. DEPENDENCY OF THE OUTPUT POWER ON THE COOLANT TEMPERATURE

(STYPE FOR KT=40 °C)

7.5.3 Effect of Installation Altitude

As the density of air drops with increasing altitude, the ability of the air to absorb heat falls.
The output power must be reduced or a larger generator must be selected.

FIGURE 11. DEPENDENCY OF THE OUTPUT POWER ON THE INSTALLATION ALTITUDE

• Figure Figure 10 on page 44 and Figure 11 on page 44 apply to SType: KT=40 °C,
installation altitude ≤ 1000 m, IP23, IC01)

7.5.4 Effect of Power Factor Cos Phi

The under-excited range from cos phi 0 to 1 is limited in case of:
• Individual operation due to the maintenance of the rated voltage by the voltage
regulator.
• Operation in parallel with the line system due to stability against loss of synchronism.
The over-excited range is limited from:
• cos phi = 1 to the rated power factor by the output power of the prime mover
• cos phi = rated power factor to 0 by the permitted rotor heating

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FIGURE 12. DEPENDENCY OF THE OUTPUT POWER ON THE POWER FACTOR

7.6 Electrical Behavior

7.6.1 Principle of Operation

FIGURE 13. BLOCK DIAGRAM OF GENERATOR WITH AUXILIARY WINDING

G1 Primary machine
G2 Excitation machine
G3 Auxiliary windings
T6 Static transforme
T24 Measuring transformer
T32 Isolating transformer
R1 Set point adjuster

The auxiliary windings G3 supply the excitation winding of the brushless three-phase AC
exciter G2 with power via the control element of the voltage regulator.
The voltage generated in the three-phase winding in the excitation rotor is rectified in a B6
bridge circuit and fed to the rotor in the generator G1.
The voltage of the primary generator is controlled with changing loads by the voltage
regulator changing the excitation current in winding G2.

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7.6.2 Voltage Regulator

The following voltage regulators can be installed in the generator, depending on customer
requirements:
• Cosimat N+
• Basler DECS 100; 125, 200
• AVK Stamford DM110
• ABB Unitrol 1000; 1010, 1020
• It is also possible to procure the generator without a voltage regulator.
• The description of the voltage regulator is in the Appendix.

7.6.3 Self-excitation, De-excitation

[Link] Self-excitation
The following options are available:
• For generators with auxiliary windings, self-excitation is provided by permanent
magnets in the excitation machine.
• In special cases, excitation can also be initiated using an external voltage of approx. 10
VDC.
Do not switch on external excitation when the generator is stationary.

[Link] De-excitation
DANGER
Hazardous voltage.
Will shock, burn or cause death.
When working on electrical systems be cautious because of the voltages. The value of the
residual voltage is above the permitted physical contact voltage. Ensure that you adhere to
the circuit diagram and use appropriate PPE.

The interruption must always be made on the regulator supply side (see order-specific
documentation). For de-excitation the current in winding J1K1 on the excitation machine G2
must be reduced to zero.
• Disconnect power supply to the regulator by removing the jumpers or using a switch as
per the circuit diagram.
• The switch contacts must be designed for 10 A and 230 V AC.
Follow the information in the related circuit diagram. After de-excitation the generator
continues to generate a residual voltage of approx. 15% of UN at the rated speed.

7.6.4 Voltage and Frequency

The generator is built to a maximum 15 kV for 50 or 60 Hz.
As standard the voltage and frequency range is defined in accordance with IEC 60034-1
zone A.

[Link] Voltage Adjustment Range

Depending on the voltage regulator used, the generators can be supplied with set point
control for installation in the switch panel.

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[Link] Static Voltage Behavior

The voltage accuracy is ± 0.5% to ± 1% under the following conditions:
• No-load to nominal load cos phi 0.1 …1
• Cold and warm machine
• Speed drop of 3%

[Link] Transient Voltage Behavior

The voltage change on a sudden load fluctuation depends on the reactance voltage drop of
the generator G1.
The magnetic circuit and the winding are designed for low transient voltage changes.
External disturbance variables for the transient voltage change are:
• The relative current transient
• The power factor
With a basic load the transient voltage change is slightly lower than on the generator with no
load.
On the application of full load with cos phi 0.8 the transient voltage change is approx. 18 to
25%.
• Refer to the order-specific data sheet for the exact values.
The time constants of the generator G1, the excitation machine G2 and the control system
used, along with the dynamic speed drop as an external effect define the change in the
voltage over time.
Up to the rated voltage, the excess excitation provided by the supply equipment is effective
on switching in loads. As a result the generously dimensioned excitation system achieves
short stabilization times.
This aspect affects the control properties.
The thermal design for continuous operation is for cos phi rated power factor. The normal
operating range is from cos phi (rated power factor normally = 0.8) to cos phi=1.

FIGURE 14. GENERATOR DIG 150I/8; 3300 KVA; 11 KV; 50 HZ; 750 MIN-1 SWITCHING IN 1000
KVA; COS ⱷ = 0.1

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FIGURE 15. GENERATOR DIG 150I/8; 3300 KVA; 11 KV; 50 HZ; 750 MIN-1 SHUTTING DOWN
1000 KVA; COS ⱷ = 0.1

[Link] Voltage Waveform Shape

The design of the magnetic circuit, the stator winding, the rotor contour and the form of the
air gap result in a sinusoidal voltage waveform.
The definitions for the evaluation of the waveform shape are:
• Telephone Harmonic Factor "THF"
• Total Harmonic Distortion "THD"
Here the requirements as per IEC 60034 are reliably met.

7.6.5 Currents
[Link] Asymmetrical Loading
The electrical design of the generator also permits asymmetrical loading.
For an asymmetrical load without loading on the other phases, the following are allowed as
per IEC 60034-1.
1. I2/IN ≤ 8% continuous, where no stator current exceeds the rated current.
2. (I2/IN)²*t ≤ 20 s for transient processes.

[Link] Overload
• The generator is sized for 1.5 times rated current for 30 s duration.
• In line with the specifications for combustion engines, an overload of 1.1 times rated
current for 1 hour is permitted once within 6 hours.
• The excitation system permits a brief overload up to 1.8 times rated current for approx.
10 s.
This short-term overload capability is available, e.g. for starting currents for
asynchronous motors.

[Link] Short-circuit Behavior

The generators are designed so that the transient voltage behavior is compliant with the
requirements provided to the manufacturer. This behavior then defines the short-circuit
behavior.
• Depending on the size of the generator, the current decays to the sustained short
circuit current within 0.3 to 0.6 s

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The primary components are sized so that the generator is able to supply 2.5-3 times the
rated current for 5 s in case of a three-phase terminal short circuit.
• For a two-phase short circuit the sustained short circuit current is a factor of 1.4 to 1.7
times higher. In this way protective devices for the reliable selective isolation of the line
system can be allocated.

FIGURE 16. INSTANTANEOUS SHORT CIRCUIT CURRENT

[Link] Harmonic Load

Loads with non-linear load currents (e.g. rectifiers) cause harmonics on the voltage
waveform.
The total harmonic distortion on the voltage waveform must be kept as low as possible to
reduce the losses that occur as a result in the generator and in the system, and to ensure
the correct function of the electrical equipment connected.

[Link] Standby Regulator

For increased reliability if the electronic voltage regulator fails, it is possible to manually or
automatically switch the generator using a standby regulator.
The entire regulator unit, including:
1. Main regulator
2. Standby regulator
3. Manual or automatic change-over circuits must be installed in the switchgear.

[Link] Star Point Treatment of Neutral Conductor Current

Generators can be operated with a solidly grounded star point or with an ungrounded star
point. The type of star point grounding is defined by the protection concept and not by the
generator.
Different possibilities for star point grounding (neutral conductor grounding):
• Low impedance (solid) grounding
• High impedance grounding
• Ungrounded star point

NOTICE
A double ground fault behaves in all circumstances like a short circuit.

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[Link].1 Low Impedance (Solid) Grounding

Differential protection for fast detection is stipulated. On grounding several star points high
equalization currents occur due to harmonics; these currents place high thermal loads on the
windings and above all on the neutral conductor.
• To reduce these currents, neutral conductor chokes are required.
Very high currents can occur for an earth fault on a phase.
• The high earth fault currents cause burning in the core and damage to the generator
winding.

[Link].2 High Impedance Grounding

In case of high impedance grounding the fault current is limited by an appropriately
dimensioned neutral conductor grounding resistor. The maximum possible ground current is
to be limited to 5 A by grounding resistors. As neutral conductor grounding resistors are
mostly designed for brief operation, selective protective devices must be provided.
In the worst case the winding insulation in the generator is loaded with a voltage to ground
increased by the factor √3. Do not sustain a fault current longer than 2 hours, or accelerated
aging of the winding insulation will occur.

[Link].3 Ungrounded Star Points

In case of a ground fault in ungrounded line systems a fault current does not occur.
The winding insulation in the generator is the loaded with a voltage to ground higher by the
factor √3.
Do not sustain a fault current longer than 2 hours, or accelerated aging of the winding
insulation will occur.
If the generator is to be operated in these conditions for an extended period, the winding
must be designed with a higher insulation class.

7.7 Parallel Operation

7.7.1 General
The parallel operation of the required number of units enables good efficiency and optimal
utilization.
The reliability is increased. In case of a failure of one unit and appropriate configuration, the
other units can take over the output power.

7.7.2 Parallel Switching Conditions

The generators to be switched in parallel and line system must comply with the
synchronization conditions, i.e. the generators must be the same in relation to the following
criteria:
1. Voltage
2. Frequency
3. Phase sequence
4. Phase position
Permissible tolerances before connecting are:
1. Voltage difference taking into account the phase position: maximum 2% of UN

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2. Frequency difference: maximum 0.6% of fN

To avoid incorrect synchronization, a synchronization control unit in the switch panel should
only enable the circuit breaker once the synchronization conditions described are met. After
switching in parallel the effective and reactive load distribution must be balanced.

7.7.3 Island Parallel Operation

• The prime movers define the effective load distribution.
• The voltage behavior of the generators defines the reactive load distribution.
The following methods of reactive load distribution are to be used:
1. Voltage droop
2. Power factor regulation

[Link] Voltage Droop

Terminal voltage is reduced as a function of the reactive current.
The distribution of the reactive load proportional to the rated output power of the generators
requires the same voltage droop.
• For adjustment to other makes the voltage droop can be continuously adjusted from
0% to a maximum of 6% of the nominal voltage.
• For stable parallel operation the voltage droop is set in the factory to 3% at nominal
current and cos phi 0.1.
This basic setting results in the following voltage droop curve:

TABLE 5. VOLTAGE DROOP

0% at cos phi = 1
1.3% at cos phi = 0.9
1.8% at cos phi = 0.8
3% at cos phi = 0.1

7.7.4 Operation in Parallel with the Line System

As the line system has a much higher short circuit power than the generators in the majority
of cases, the number of units operating in parallel is irrelevant. As a result there is no
significant effect as a result of this configuration.
Voltage fluctuations emanate largely from the line system.
In case of operation in parallel with the line system a power factor regulator is to be used.
As a result the power factor set remains constant in case of line voltage fluctuations as well
as with varying generator loads.
If a specific power factor is required at the line transition point, the current transformer for
the power factor regulator must be arranged at this point.

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[Link] Power Factor Regulation

This process is used for operation in parallel with the line system. For the Cosimat N+, an
additional regulator for power factor regulation controls the generator voltage regulator. This
additional regulator, in the generator or in the switchgear, is used to maintain the power
factor set point.
• For digital voltage regulators (e.g. DECS, Unitrol 1000) the power factor regulator is
integrated.
As a result, the generator current has also to be monitored at the generator terminals as a
function of the power factor.

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8 Commissioning and Starting
8.1 General
The commissioning report is an important document for future servicing and maintenance of
the generator as well as any troubleshooting. Commissioning can only be considered
complete once an adequate commissioning report has been prepared and archived.
It is imperative that the commissioning report is submitted on making claims under the
warranty. For contact information see Section 12.1 on page 99.

8.2 Check the Mechanical Installation

1. Before commissioning check the alignment of the generator.
2. Review the alignment report and make sure that the generator is aligned in accordance
with the manufacturer's alignment specification (see Section 6.4 on page 30)
3. The alignment report must always be included with the commissioning report. Make
sure the generator is correctly anchored on the foundation.
4. Check the foundation for cracks and its general condition.
5. Make sure the fastening screws are tightened to the correct torque.
6. Check the direction of rotation of the generator, looking at the generator shaft DE.
7. Make sure the lubrication system is operational and running before the rotor is turned.
8. On generators with roller bearings turn the rotor by hand (before the generator has
been coupled) and make sure it rotates freely and no abnormalities, e.g. scraping or
grating noises can be heard.
9. Check the installation of the main terminal box and the cooling system.
10. Check the ambient conditions and the function of the cooling system.
11. Check the connections for the oil and cooling water lines and check them for leaks
during operation.
12. Check the pressure and the flow of oil.
13. Check the pressure and the flow of cooling water.

8.3 Check the Electrical Installation

Before the generator is started for the first time, after an extended period at standstill or
during general servicing work, measure the insulation resistance, see Section 7.4.4 on
page 39.

8.4 Controller and Protective Equipment

8.4.1 General
If the generator shuts down or in the event of an alarm, the reason must be found and
corrected before re-starting the generator. The generator is equipped with several
temperature sensors (PT100) in order to avoid overheating of the generator. These sensors
must be connected to a temperature monitoring and protection system.

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The temperature alarm level for resistive temperature sensors must be set as low as
possible. The level can be determined based on test results or the operating temperature
measured. The temperature alarm can be set 5 - 10 K (11 - 20 °F) higher than the operating
temperature of the generator with maximum load at the highest possible ambient
temperature.
If a temperature monitoring system with two functions is used, the lower level is normally
used as the alarm level and the higher level as the shutdown level.

8.4.2 Stator Winding Temperature

Standard stator windings are manufactured in accordance with temperature rise class F.
This class has a temperature limit of 155 °C (300 °F). A high temperature will result in the
insulation aging more quickly and shortening the service life of the windings. Take this into
account when defining the limits for alarm triggering and thermal shut down.

[Link] Maximum Temperature Setting

Carefully consider the application environment when setting the shutdown values during
commissioning. After a test run at nominal load for approx. 3-4 hours, the temperature
sensors must be set approx. 5 K above the values measured. During this process make
sure that the maximum possible cooling air temperature is taken into account.
This statement applies in particular to the temperature monitoring for the roller bearings/plain
bearings, as a temperature increase is normally indicative of a bearing damage. Warning
and shut down levels must be set close to the nominal temperature.
Do not exceed the temperatures stated in Table 6 on page 54.

[Link] Maximum Settings for the Stator Temperature - Class F

TABLE 6. WARNING TEMPERATURES AND SHUTDOWN TEMPERATURES FOR
STATORS

Insulation class Warning °C Shutdown °C

Heating to B 125 130
Heating to F 140 145
Heating to H 155 160

8.4.3 Monitoring the Bearing Temperature

[Link] General
The bearings can be equipped with temperature sensors to monitor the bearing
temperatures. The viscosity of the grease or oil used reduces at a higher temperature. If the
viscosity becomes too low, it is no longer possible to form a film of lubricant in the bearing
and the bearing will be damaged which in turn will damage the shaft.
If the generator is equipped with resistive temperature sensors, monitor the temperature of
the bearings continuously. If the temperature of a bearing starts to increase unexpectedly,
the generator must be shut down immediately, as the temperature increase may be
indicative of a bearing failure.

[Link] Maximum Temperature Settings for Bearings

If not stated otherwise on the outline drawing, the following warning and shutdown limits
apply.

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TABLE 7. WARNING TEMPERATURES AND SHUTDOWN TEMPERATURES FOR

BEARINGS

Bearing class Warning °C Shutdown °C

Roller bearings 75 90
Plain bearings 85 90

[Link] Maximum Temperature Settings for Bearings - DIG 167

If not stated otherwise on the outline drawing, the following warning and shutdown limits
apply for the plain bearings in the generator series DIG 167.

TABLE 8. WARNING TEMPERATURES AND SHUTDOWN TEMPERATURES FOR

GENERATORS DIG 167

Bearing class Warning °C Shutdown °C

DIG 167 c/d/e 103 105
DIG 167 f/g/h 107 110
DIG 167 i/k 117 120

• These warning values and shutdown values can only be achieved by using the
synthetic oils stated on the outline drawing.

[Link] Protective Systems

The generator must be protected against malfunctions, failures and overloads that could
damage the generator. The protection must comply with the requirements and regulations in
the specific country in which the generator is used. The manufacturer of the generator is not
responsible for the adjustment of the protective systems.

8.5 First Run

8.5.1 General
The first test start is a standard procedure after installation and alignment, making
mechanical and electrical connections, commissioning and activation of protective systems.
The first start must be made without load.

8.5.2 Before Starting

Before the first test start the generator and its equipment are visually inspected. Make sure
that all the necessary work, checks and settings have been made.
Before the first test start the following checks and measures prior are to be made:
1. Check the coupling and the coupling guard for correct assembly and loose parts.
2. Check that any fitted grounding brushes are free to move and are in contact with the
shaft.
3. The plain bearings and, if required, the oil supply system must have been filled with the
stipulated oil to the correct level. Then switch on the oil supply system, if necessary.
4. In case of water-cooled generators, place in operation the water cooling circuit. Check
the flanges and cooling unit for leaks.
5. Compare the wiring and the bus bar connections with the circuit diagram.
6. Check grounding connections and grounding systems.

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7. Check start, stop, protective and alarm relays in each system.

8. Check the insulation resistance of the windings and other equipment.
9. Fit the covers to the generator.
10. Clean generator and surrounding area.
11. Check that no loose parts (bolts etc.) are in the terminal box. If so, these must be
removed.
12. Check the fan rotation direction.
13. Check the rotating parts do not touch any fixed components.

8.5.3 Starting
First check the direction of rotation of the generator on starting for the first time. If external
fan motors are installed, check the direction of rotation. Check that the rotating parts do not
touch any fixed components.
If the generator does not have a fixed bearing and the generator is started with a flexible
coupling, it is normal for the shaft to move axially before it stabilizes. If installed, check the
adjustment indicator and correct the alignment in case of errors (see Section 6.4 on page
30).

8.5.4 Direction of Rotation of the Generator and External

Motors
The generator must be operated with the direction of rotation stated on the rating plate.
Check the direction of rotation of the generator based on the outline drawing.
Check the direction of rotation of any external motors installed (pumps, fans etc.). The
direction of rotation is given by an arrow near the motor.

8.5.5 Ground Fault Monitoring

• Check the function of the ground fault monitoring.
• If the generator has a brush lifting device, check its position and function. Refer to
Section [Link] on page 87.

8.6 Operate the Generator for the First Time

8.6.1 Monitoring During Operation
During operation for the first time check whether the generator is functioning correctly.
Constantly monitor the amount of vibration, the temperature of the windings, bearings and
regulators.
• Check the operating load on the generator by comparing the load current with the value
stated on the generator rating plate.

[Link] Check the Excitation

1. Check voltage rise during automatic operation.
2. Check regulation range of the automatic voltage regulation.
3. Check regulation range of the voltage with manual excitation.
4. Check switching from voltage regulation to current regulation with manual excitation.

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[Link] Check the Synchronization Chain

The synchronization check is made in 2 stages.
1st stage:
The two measuring circuits in the synchronization chain are supplied from the same source.
Check the following points:
1. The zero point for the synchronoscope
2. The zero indication on the differential voltmeter
3. The frequency meter
2nd stage:
One measuring transformers is supplied from the generator and the other from the line
system to compare the related rotating fields.

[Link] Full Load Test

After stabilization, the following must be measured:
1. Stator winding
2. Cold air - warm air
3. Bearing on coupling end AS (DE)
4. Bearing on opposite end to the coupling BS (NDE)
5. Vibration measurement on the generator bearings (see Section 10.5 on page 75).

[Link] High-speed De-excitation

High-speed de-excitation is only necessary in case of certain malfunctions. For example,
false synchronisation or if the generator is suddenly separated from the mains.
De-excitation switches are not included in the items supplied.

8.7 Check the Generator in Operation

During the initial days of operation, it is important to monitor the generator carefully for
changes in vibration, temperature or abnormal noises.

8.7.1 Bearings
[Link] Generators with Roller Bearings
• Do not re-grease the generator during commissioning.
• If the generator has been protected against corrosion, remove the corrosion protection
before starting for the first time.
The type of grease used originally is stated on the rating plate on the generator. Refer to the
allowed grease types in Section [Link] on page 79, types of greases.
The temperature of the bearings increases at the start due to excess grease. After a few
hours the excess grease is driven out and the temperature of the bearing drops to the
normal operating level. See Section [Link] on page 79
Adhere strictly to the re-lubrication interval. The interval between two lubrication intervals
must not exceed 12 months under any circumstances. After the generator has been
operated for several hours, measure the vibration and record the values for subsequent
reference.

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8.7.2 Vibration
You will find a detailed description of the vibration in Section 10.5 on page 75.

8.7.3 Temperature Level

Check the temperatures of the bearings, stator windings and cooling air with the generator
running. (See Section [Link] on page 54)
The winding and bearing temperatures only reach a stable temperature after several hours
at maximum load.
The temperature of the stator winding depends on the load on the generator. If it is not
possible to achieve full load during or just after commissioning, the actual and temperature
values must be recorded and noted in the commissioning report.
1. Record the temperatures at the temperature sensors for the windings and if necessary
for the bearings.
2. Check the temperature frequently to ensure it remains below the limits.
3. Continous temperature monitoring is required.

8.7.4 Heat Exchanger

• Before starting, make sure the connections are secure and there are no leaks in the
system.
After the generator has run for a time it is necessary to check the cooling system.
• Make sure the coolant and, if necessary, the air can circulate without hindrance.

8.8 Shut Down the Generator

The procedure to shut down the generator depends on the application. Before
commissioning clarify the concept for the shutdown procedure with the manufacturer of the
drive unit and the switchgear.
However, it is recommended to:
1. Reduce, if necessary, the load in the load system
2. Disconnect the generator from the line system
3. Make sure there is no condensation in the generator.
4. Switch on any anti-condensation heaters, if these are not switched automatically by the
switchgear.
5. For water-cooled generators, interrupt the flow of cooling water to prevent condensation
inside the generator.

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9.1 General
CAUTION
Hot Surfaces.
Will burn.
Use PPE and measure the temperature of the surfaces before touching them.

NOTICE
Generator overload can result in serious damage.

NOTICE
Always observe the safety precautions.

To ensure trouble-free operation, the generator must be carefully serviced and monitored.
Before starting the generator, ensure the following:
1. Check the plain bearings for the correct oil and oil level according to the technical data
and the outline drawing
2. All cooling systems are operating
3. Check the generator and all attachments for leaks, soiling or damage
4. Check that there is no servicing work in progress
5. The operators and the system are ready for the machine start.
In case of deviations from the normal operating state, e.g. raised temperatures, noise or
vibration, shut down the generator and find the cause. If in doubt, contact the manufacturer.

9.2 Normal Operating Conditions

The generator is designed for operation in normal operating conditions according to the
order specification and manufacturer's internal regulations.

9.3 Number of Starts

The number of starts and shutdown processes in succession depends on the design of the
generator. If in doubt, contact the manufacturer for this information.
Use a counter to check the number of starts. The servicing intervals are based on the
related operating hours, see Chapter 10 on page 65.

9.4 Monitoring
Check the generator at regular intervals. Abnormal operating conditions must be
investigated.

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The objective of monitoring inspection is to make operating personnel familiar with the
system. This aspect is very important for the timely identification and rectification of
deviations and malfunctions. Normal operational monitoring includes logging the operating
data such as load, temperatures and [Link] data form a useful basis for servicing and
maintenance.
During the initial operating period (up to 200 hours) monitor the generator particularly
intensively. Check the temperature of the bearings and windings, the load, the current, the
cooling, the lubrication and vibration several times a day.
In the subsequent weeks and months (200-1000 hours) a daily check is sufficient. Record
the results of the check in the inspection report and archive it at the operating organization.
Subsequently, the interval between the inspections can be further extended if operation is
continuous and stable.

9.4.1 Bearings
Monitor bearing temperatures (see Section 8.4.3 on page 54) and lubrication (see Section
10.6 on page 78).

9.4.2 Vibration
Monitor the vibration level in the generator. See Section 10.5 on page 75.

9.4.3 Stator Temperatures

Check the temperatures of the stator windings and cooling air with the generator running.
(See Section 8.4.2 on page 54)

9.4.4 Heat Exchangers

Make sure the connections are secure and there are no leaks in the system. Make sure the
coolant and, if necessary, the air can circulate freely. (See Section 10.9.3 on page 89).

9.4.5 Slip Ring Units

Monitor the wear on the carbon brushes and replace them before the wear limit is reached.
(See Section 10.8.7 on page 87).

9.4.6 Documentation of Operation

The documentation of operation includes logging the operating data including the load,
temperatures and vibration. This data form a useful basis for servicing and maintenance.

9.5 Shutting Down

WARNING
Hazardous volatge.
Will shock, burn or cause death.
Use appropriate PPE and make sure that no voltage is present. There may be electrical power
present in the auxiliary terminal box for the anti-condensation heater.

See Section 8.8 on page 58.

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9.6 Anti-condensation Heaters

Anti-condensation heaters increase the air temperature in the area of the windings to
prevent the formation of condensation. Ideally the anti-condensation heater switches on
automatically when switching off the generator.

9.7 Flashover Pressure Protection

NOTICE
If a flashover pressure event occurs in the terminal box, it is imperative that the entire
generator is inspected without delay.

It is not sufficient to simply renew the flashover protection. A protective system for pressure
relief is installed in Cummins generators; this system limits the extent of damage due to an
event in the terminal box. A pressure event can occur if a fault causes flashover in the
terminal box. During this process air and other materials suddenly expand to several times
their initial volume due to the extremely high temperature.
Flashover protection attempts to reduce the pressure caused by this reaction in a defined
manner using predetermined breaking points so that the effects of the event can be
minimized. The objective is to exclude a hazard for personnel.
For this purpose a predefined breaking point for pressure relief is integrated into the sleeve
on the terminal box. This feature consists of four individual plates that are arranged to form a
square plate, or a metal film. The flashover protection is mounted pointing towards the
generator to prevent harm to any person nearby and to minimize any debris thrown out.
The flashover protection must be sealed so that the required degree of protection is
achieved, but the pressure relief function is not affected.

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FIGURE 17. PROTECTION DEVICE (1)

9.8 Firefighting and Extinguishing Agents

9.8.1 General
NOTICE
If a flashover pressure event occurs in the terminal box, it is imperative that the entire
generator is inspected without delay.

Pay attention to the generally applicable and national safety distances to electrical systems,
e.g. DIN VDE 0132 (Fire-fighting in the area of electrical systems). Make sure regular
inpection and tests are done.
Pay attention to the generally applicable and national health and safety regulations.
During extinguishing tasks in electrical systems and in their vicinity, take precautions to
prevent an electric shock hazard for the fire fighters or operators.
This requirement also involves:
• The use of suitable tools and equipment, e.g.
• Insulated tools
• Grounding rods
• Short circuiting devices
• Insulating covers

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• Insulating protective trim panels

The minimum distances required between extinguishing agent outlet opening and live parts
of the electrical system are intended to protect the personnel undertaking the extinguishing
task against the direct effects of electrical power during the extinguishing task.

9.8.2 Extinguishing Agents

The following can be used as extinguishing agents:
• Water
• Foam
• Powder
• Carbon dioxide
Select the extinguishing agents taking into account their suitability and use limitations.
While taking into consideration the disadvantages for fighting the fire as well as for the
general public, shutdowns are only to be made with the agreement of the operating
organization.
Extinguishing agents must only be used in the area of live electrical systems if the minimum
distances to be maintained have been determined by the operating organization as a
preparatory measure.

[Link] Extinguishing Agent - Water

Fires in the area of electrical systems are to be fought using a spray jet as far as possible.
In case of water containing other substances, such as wetting agents or elements that
increase the conductivity, such as sea water and the like, conductive coatings on insulators
are possible.

[Link] Extinguishing Agent - Foam

Low voltage systems:
Foam must only be used on electrically isolated systems; neighboring systems are also to
be electrically isolated, if necessary. The use of type-tested extinguishing equipment
approved for use in electrical systems is excluded from this limitation.
High voltage systems:
Foam must only be used on electrically isolated systems, without exception; neighboring
parts of systems are also to be electrically isolated, if necessary.

[Link] Extinguishing Agent - Powder

Coatings of extinguishing foam can be conductive in higher electrical field strengths, created
by high voltage (voltage above 1 kV) under the effect of temperature, moisture and humidity,
and currents similar to short circuits can flow. The resulting arc faults represent a mortal
danger for persons in the vicinity and hazard for the system. For this reason extinguishing
powders must only be used if these systems are dry.
Avoid indirect hazards, to the persons in the vicinity and the high voltage system itself, due
to conductive coatings.
Only use extinguishing powder that does not form coatings that are difficult to clean (e.g.
vitrifiable coatings with ABC powder) on the parts of the system. Avoid the use of
extinguishing powder in the area of system sensitive to dust (such as measuring and control
systems, distribution cabinets with contactors and relays etc.

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[Link] Extinguishing Agent - Carbon Dioxide (CO2)

WARNING
Suffocation by carbon dioxide.
Carbon dioxide is heavier than air and causes asphyxiation from 8% by volume.
Caution on use in small, poorly ventilated rooms. Pay attention to the warning information on
the extinguishing equipment.

Carbon dioxide is not electrically conducting and does not leave any residue. It can be used
on live systems without restriction.

9.8.3 Cleaning After Fire-fighting

Never place generators or systems back in operation that have not been cleaned adequately
and their function fully checked.

NOTICE
Extinguishing agent residue can have a highly corrosive effect on parts of the generator.
Contact the manufacturer of the extinguishing agent for information on suitable measures to
counteract this effect and regularly check their effectiveness.

After all necessary measures for firefighting, immediately start to remove extinguishing agent
residue.
Also check if parts of a system not directly affected by a fire may have been damaged or
soiled by extinguishing agent.
The manufacturer does not provide any warranty on generators and their attachments if
these are soiled by extinguishing agent.

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10.1 Preventive Servicing
A generator is often an important element of a larger installation.
If the generator is correctly monitored and serviced, the generator will function correctly and
reliably for a long time.
The purpose of the servicing is therefore:
• To ensure that the generator operates reliably and without anomalies or interruptions
• To be able to plan the necessary maintenance work in advance to minimize the
downtimes.
The normal monitoring during operation includes the recording of operating data, e.g. load,
temperature and vibration, as well as checking for correct lubrication and measuring the
insulation resistances.
During the first days and weeks after commissioning or undertaking maintenance measures,
the generator must be monitored intensively. The temperature of the bearings and windings,
the load, the current, the cooling, the lubrication and vibration are to be checked regularly.
This section contains recommendations in relation to a servicing schedule as well as
instructions for normal servicing tasks. These instructions and recommendations are to be
read carefully and used as the basis during the planning of the servicing schedule. Please
note that the servicing recommendations stated in this section represent a minimum. More
intensive maintenance and monitoring will increase the reliability and service life of the
generator. The servicing should be intensified if there are local conditions with high
requirements or extreme reliability is required. Cummins Service will be pleased to assist
you in case of questions on the specific requirements categorization or servicing
recommendations.
The data recorded during the monitoring and servicing will make it easier to foresee and
plan further measures. If you detect anomalies, the instructions in troubleshooting will assist
you in the location of the causes.
We recommend the use of checklists (in the Appendix) for the preparation of servicing
schedules. The actual servicing as well as any troubleshooting must be done by specialist
personnel. Cummins Service will be pleased to provide assistance with this task. You will
find the related contact information at the start of the documentation.
A key element of the preventive servicing is the availability of a selection of suitable spare
parts. To be able to have quick access to crucial spare parts in case of need, you should
keep a basic range in stock.

10.2 Safety Precautions

DANGER
Hazardous voltage, will shock, burn or cause death.
When the generator rotor turns, the exciter generates a voltage.
Prevent the rotor turning before you open the terminal box. Never open the terminal box or
touch the unprotected terminals while the generator rotor is rotating. Follow safety
instructions at the start of the manual. See Chapter 2 on page 3.

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WARNING
Hazardous voltages, rotating parts and hot surfaces will shock, burn or cause loss of limbs
or death.
Before starting work on the unit, it is to be shut down and locked. During the work make sure
that a potentially explosive atmosphere is not produced and is not present.

Qualified, specialist personnel trained in the necessary servicing procedures and tests are to
be tasked with the servicing of the electrical system and the installation.
For general safety information, see safety instructions at the start of the manual. See on
page 3. Before starting any work on electrical systems, take general electrical safety
precautions and follow local regulations to prevent injuries. This action should be taken in
accordance with the instructions from the operating organization's safety personnel.
Safety rules before starting work:
1. Switch off
2. Lock out
3. Check all lines and equipment are dead
4. Ground and short-circuit phases
5. Cover, partition and screen off adjacent line sections.

10.3 Recommended Servicing Schedule

This section represents a recommended servicing schedule. The servicing should be
intensified if there are local conditions with extreme requirements or extreme reliability is
required. It is also highlighted that even on following this servicing schedule, the normal
monitoring and observation of the state of the generator are required.
Please note that in the servicing schedule below, accessory parts may be mentioned that
are not present on all generators, even though the schedules have been adapted to this
generator.
The servicing schedule is based on four servicing intervals; the related intervals are
dependent on the operating hours. The amount of effort required and the downtimes vary:
Servicing interval 8000 operating hours
This servicing interval includes visual inspections and minor servicing work. The purpose of
the servicing is to check whether problems are developing before they result in failures and
unplanned interruptions for servicing. The service inspection also identifies further
measures.
The servicing is dependent on the type and the installation of the generator as well as the
feasibility of undertaking the inspection. The tools for this servicing work are normal
servicing tools.
The servicing is to be done after an interval of 8,000 equivalent operating hours or one year
after commissioning or servicing at the latest.
Servicing interval 25000 operating hours
This servicing interval can require the removal of generator components. The purpose of this
servicing is to check inaccessible components to safeguard long-term operation.
The servicing is dependent on the type and the installation of the generator as well as the
feasibility of undertaking the inspection. The tools for this servicing include special servicing
tools.

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The servicing is to be done after an interval of 25,000 equivalent operating hours or three
years after commissioning or servicing at the latest.
Servicing interval 50000 operating hours
This servicing interval can require the removal of generator components. The purpose of this
servicing is to check inaccessible components to safeguard long-term operation.
The servicing is dependent on the type and the installation of the generator as well as the
feasibility of undertaking the inspection. The tools for this servicing include special servicing
tools.
The servicing is to be done after an interval of 50000 equivalent operating hours or 6 years
after commissioning at the latest.
Servicing interval 100000 operating hours
This servicing interval requires a complete generator overhaul.
The purpose of this servicing is to equip the generator for continued long-term operation.
The servicing is dependent on the type and the installation of the generator. The servicing
can only be done by appropriately qualified personnel.
The servicing is to be done after an interval of 100000 equivalent operating hours after
commissioning.

10.3.1 Generator
SERVICING WORK TYPE Servicing Intervals

Every 25,000 hours or 3 years

Every 8,000 hours or 1 year

50,000 hours or 6 years

During Commissioning
Generator in operation
System

Repair or Replace
Test and Measure
Visual inspection

100,000 hours
X = required
Clean

* = if necessary
O= see rating
plate/documentation
Machine operation - Starting,
shutting down, vibration * X X * X X
measurement
General overhaul * X
Coupling and foundation - * X X X X
Specially cracks, rust, alignment
General

Paint finish - Rust, condition X X X X

Screw joints - Strength of all X X X X
screw joints
Foundation screws - Fastening, X X X X
condition
Grounding - Connection, X X X X
function
Vibration X X X X

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10.3.2 Main Electrical Connections

Servicing Work Type Servicing Intervals

Every 25,000 hours or 3 years

Every 8,000 hours or 1 year

50,000 hours or 6 years

During commissioning
Generator in operation
System

Test and measure

Visual inspection

Repair or replace

100,000 hours
X = required

Clean
* = if necessary
O= see rating
plate/documentation
Main electrical cables - Wear, X X X X
fastening
Main electrical cables -
Oxidation, fastening, cracks, X X X X
Main electrical connections

screw joints
Main electrical connections - X X X X
Insulation, resistance
Main electrical cables - Strain X X X
relief X
Regulator - Function X X X X
Current transformers, voltage
transformers, isolators - General X X X X
condition, fastening,
connections
Cable routes - Condition of the
cables to the generator and in X X X X
the generator

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10.3.3 Stator and Rotor

SERVICING WORK TYPE Servicing Interval

Every 25,000 hours or 3 years

Every 8,000 hours or 1 year

50,000 hours or 6 years

During Commissioning
Generator in operation
System

Test and measure

Visual inspection

Repair or replace

100,000 hours
X = required

Clean
* = if necessary
O= see rating
plate/documentation
Stator - Fastening, cracks, weld X X X
seams
Insulation of the stator winding -
Wear, cleanliness, insulation X X * X X
resistance,
Stator winding assembly - X * X X
Damage to insulation
Exciter stator - rotor Resistance X X X
Rectifier carrier - Fastening, X X * X X
cable, diodes, varistors
Auxiliary windings - Resistance X X X
measurement
Stator and rotor

Stator slot wedges - Movement; X X

firm seating
Stator terminals - Fastening, X X X X
insulation
Instrumentation - Condition of X X X
the cables and cable ties
Rotor winding insulation - Wear,
cleanliness, insulation X X * X X
resistance
Anti-condensation heaters - X X * X X
Operation, insulation resistance
Shaft position axial alignment X * X X
Connections on the rotor - X X X
Fastening, general condition
Grounding brushes - Operation * X O
and general condition
Fan - Soiling, condition X X X

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10.3.4 Accessories
SERVICING WORK TYPE Servicing Intervals

Every 25,000 hours or 3 years

Every 8,000 hours or 1 year

50,000 hours or 6 years

During Commissioning
Generator in operation
System

Repair or Replace
Test and Measure
Visual inspection

100,000 hours
X = required

Clean
* = if necessary
O= see rating
plate/documentation
Accessories

PT-100 elements (stator, air * X X X

cooling, bearings) - Resistance
Auxiliary terminal box - General
condition, terminals, condition of X X * X X
wiring

10.3.5 Slip Ring Units

SERVICING WORK TYPE Servicing Intervals

Every 25,000 hours or 3 years

Every 8,000 hours or 1 year

50,000 hours or 6 years

During Commissioning
Generator in operation
System

Repair or Replace
Test and Measure
Visual inspection

100,000 hours
X = required
Clean

* = if necessary
O= see rating
plate/documentation
Assembly - Fastening, * X * * X X
insulation, connections
Slip Ring Units

Brush holder - Alignment, X X * * X X

function
Brushes - Wear, function X X * X X
Slip ring wiring X X X
Slip rings - Wear, roundness, X X X
patina

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10.3.6 Lubrication System and Roller Bearings

SERVICING WORK TYPE Servicing Intervals

Every 25,000 hours or 3 years

Every 8,000 hours or 1 year

50,000 hours or 6 years

During Commissioning
Generator in operation
System

Repair or Replace
Test and Measure
Visual inspection

100,000 hours
X = required

Clean
* = if necessary
O= see rating
plate/documentation
Lubrication system and roller bearings

Bearings - During operation;

general condition, noise, X X X X X
vibration
Bearing condition analysis - X X X X
SPM measurement
Surplus grease - Condition and X X X
discharge
Lubrication system - freedom X * * X
from leaks and function
Seals - Freedom from leaks X * X
Grease - paint and condition X * X
Re-lubrication interval X O
Bearing insulation - insulation X X
resistance

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10.3.7 Cooling System

SERVICING WORK TYPE Servicing Intervals

Every 25,000 hours or 3 years

Every 8,000 hours or 1 year

50,000 hours or 6 years

During Commissioning
Generator in operation
System

Repair or Replace
Test and Measure
Visual inspection

100,000 hours
X = required

Clean
* = if necessary
O = see rating
plate/documentation
Generator cooling

Fan - Operation, condition X * X X

Generator inlet air Hindrance - X X X
amount
Filter - Cleanliness, operation X * * O
Air paths - Cleanliness,
operation X * X X

Fans - Operation, condition X * X X

Air-air cooling

Pipes - Cleanliness, operation X * X X

Ducts - Cleanliness, operation X * X X
Metal ribs - General condition X * X X
Vibration dampers - Condition X * X X
and function
Heat exchangers -Freedom X X X
from leaks, operation, pressure
Cooler condensate drain - X * X X
Function, cleanliness
Pipes - Cleanliness, corrosion, X X X
Air-water cooling

freedom from leaks

Ducts - Cleanliness, operation X X X
Cooler housing - Freedom from X * X X
leaks, condition
Gaskets and seals -Freedom X * X
from leaks, condition, cracks
Metal ribs - General condition X * X
Vibration dampers - Condition X * X X
and function
Check for leaks X X X * X X

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10.3.8 Safety
SERVICING WORK TYPE Servicing Intervals

Every 25,000 hours or 3 years

Every 8,000 hours or 1 year

50,000 hours or 6 years

During Commissioning
Generator in operation
System

Repair or Replace
Test and Measure
Visual inspection

100,000 hours
X = required

Clean
* = if necessary
O= see rating
plate/documentation
Alarm system - Function and X X X
correctness
Safety

Warning and shutdown

temperatures - Correct X X X
adjustment, function
Overcurrent shutdown Function X X X X
Check differential protection X X X X

10.4 Servicing - General Structure

To ensure a long service life of the general structure of the generator, the exterior of the
generator is to be kept clean and is to be regularly checked for rust, leaks and other faults.
Soiling on the external parts of the generator will subject the generator to corrosion and can
affect its cooling.

10.4.1 Strength of Screw Fasteners

NOTICE
Loose fastenings on these parts can result in sudden and serious damage. Check and re-
tighten the fastenings regularly.

The strength of the screw fasteners is to be checked regularly. In particular attention is to be

paid to the base fastening and the screws for the attachments; these screws must always be
correctly tightened.
See the general values for tightening torques in Table 9.

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TABLE 9. GENERAL TIGHTENING TORQUES (STEEL - STEEL)

Thread size Property class Tightening torque Nm Tightening torque

(foot-pound)
M4 8.8 3.0 2.2
10.9 4.6 3.4
12.9 5.1 3.8
M5 8.8 5.9 4.4
10.9 8.6 6.3
12.9 10.0 7.4
M6 8.8 10.1 7.4
10.9 14.9 11.0
12.9 17.4 12.8
M7 8.8 16.8 12.4
10.9 24.7 18.2
12.9 28.9 21.3
M8 8.8 24.6 18.1
10.9 36.1 26.6
12.9 42.2 31.1
M10 8.8 48 35
10.9 71 52
12.9 83 61
M12 8.8 84 62
10.9 123 91
12.9 144 106
M14 8.8 133 98
10.9 195 144
12.9 229 167
M16 8.8 206 152
10.9 302 223
12.9 354 261
M18 8.8 295 218
10.9 421 311
12.9 492 363
M20 8.8 415 306
10.9 592 437
12.9 692 363
M22 8.8 567 418
10.9 807 595
12.9 945 697
M24 8.8 714 527
10.9 1017 750
12.9 1190 878

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Thread size Property class Tightening torque Nm Tightening torque

(foot-pound)
M27 8.8 1050 774
10.9 1496 1103
12.9 1750 1291
M30 8.8 1428 1053
10.9 2033 1499
12.9 2380 1755
M33 8.8 1928 1422
10.9 2747 2026
12.9 3214 2371
M36 8.8 2482 1831
10.9 3535 2607
12.9 4136 3051
M39 8.8 3208 2366
10.9 4569 3370
12.9 5346 3943

NOTICE
The values in the table General tightening torques are of a general nature and do not apply to
components such as diodes, auxiliary isolators, bearings, cable terminals or pole fastenings,
bus bar terminals, overvoltage arrestors, current transformer fastenings, rectifiers or
varistors or other electrical connections, or if another value is stated in this manual or in the
manufacturer's documentation.

10.5 Vibration
High or increasing vibration levels are indicative of changes in the condition of the generator.
Normal levels vary widely as a function of the use, the type and the generator foundation.
Typical causes of high vibration levels are:
• The alignment has changed
• Bearing wear or bearing damage
• Vibration is occurring on machines connected or the vibration has changed
• Fastening or foundation screws have loosened
• Rotor imbalance has changed
• Couplings are worn
The following instructions are part of the following two ISO standards:
ISO 10816-3 Mechanical vibration - Evaluation of machine vibration by measurements on
non-rotating parts: Part 3: Industrial machines with nominal power above 15 kW and nominal
speeds between 120 r/min and 15 000 r/min when measured in situ
ISO 8528-9 Reciprocating internal combustion engine driven alternating current generating
sets: Part 9: Measurement and evaluation of mechanical vibrations.

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10.5.1 Measuring Methods and Operating Conditions

[Link] Measuring Equipment
The measuring equipment must be able to measure the effective broadband vibration with a
linear frequency response from at least 10 Hz to 1000 Hz. Depending on the vibration
criteria this aspect can require measurements of displacement or velocity or a combination
of the two. The lower limit for the frequency range with a linear frequency response must,
however, not be less than 2 Hz for machines with speeds of 600 rev/min and below.

[Link] Measuring Points

Measurements are normally made on accessible parts of the generator. Make sure that the
measurements appropriately reflect the vibration in the bearing housing and do not contain
any local resonances or amplification. The locations and directions of the vibration
measurements are to be selected so that they offer appropriate sensitivity for the generator
dynamic forces. Typically this aspect requires two orthogonal radial measuring points on
each bearing, as shown in Figure 18 on page 76. The transducers can be applied at any
angular position on the bearings. Generators are measured in vertical, axial and horizontal
directions. The measuring points and measuring directions are to be noted together with the
measured values.

FIGURE 18. DIN 10816-3 - SPECIFICATION FOR MEASURING POINTS

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10.5.2 Definition in Accordance with ISO 10816-3

ISO 10816 -3 provides a general description of the two evaluation criteria for determining the
magnitude of the vibration on different machine classes. One criterion takes into account the
magnitude of the broadband vibration observed, the other takes into account changes in
magnitude (both increases and reductions).

TABLE 10. ISO 10816-3

Declared engine Rated power output of the generating set Vibration velocity V rms
speed Value 1 mm/s
revs/min (cos phi = 0.8) kVA KW

> 1300 but < 2000 > 250 > 200 20

> 720 but < 1300 > 250 but < 1250 > 200 but < 1000 20
> 1250 > 1000 18
=< 720 > 1250 > 1000 15

10.5.3 Definition in Accordance with ISO 8528-9

ISO 8528-9 refers to a broad band of frequencies between 10 and 1000 Hz. The following
table is an extract from ISO 8528-9 (Table C.1, value 1). This simplified table contains the
vibration limits by kVA range and the speed for acceptable generator set operation.

TABLE 11. ISO 8528-9

Division of the vibration magnitude zones

Large machines with nominal Medium-sized machine with
output powers over 300 kW nominal output powers 15 kW
and not more than 50 MW to 300 kW
Electrical machines with axis Electrical machines with axis
heights H > 315 mm heights 160 mm < H < 315 mm
Sub-assembly Zone limit Effective Effective Effective Effective
value for the value for the value for the value for the
vibration vibration vibration vibration
displacement velocity displacement velocity
µm mm/s µm mm/s
Rigid A/B 29 2.3 22 1.4
B/C 57 4.5 45 2.8
C/D 90 7.1 71 4.5
Elastic A/B 45 3.5 37 2.3
B/C 90 7.1 71 4.5
C/D 140 11 113 7.1

10.5.4 Warning Values and Shutdown Values

We recommend regularly checking the condition of the generator using a suitable instrument
for vibration monitoring during servicing, or checking the condition continuously. For this
purpose it is best to measure initial values and to use these values as the basis for the
regular monitoring of the generator to detect possible degradations. The warning values and
shutdown values are to be adjusted in accordance with the related standard and in
combination with the existing operating conditions.

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10.6 Servicing the Bearings and the Lubrication

System
This section addresses the most important servicing work on the bearings and on the
lubrication system.

10.6.1 Roller Bearings

[Link] Bearing Design
After the bearing has been filled with grease for the first time, it is not normally necessary to
top-up the grease for a long time. However, in difficult operating conditions the grease must
be regularly topped-up or replaced. For this purpose the bearing housing is designed so that
the grease is easy to top-up. The bearing housing is designed so that the old grease will be
replaced with fresh grease. In the bearing covers there is a space where the grease can be
introduced. The grease runs slowly through the bearings and old grease, which escapes on
the opposite side of the bearing, is drained via the grease regulator. The grease is guided to
the exterior via the grease outlet.

[Link] Rating Plate: Lubrication and Re-lubrication Intervals

NOTICE
It is imperative the information stated on the rating plate is taken into account during the
operation and servicing of the generator.

All generators are supplied with rating plates that are attached to the stator. The rating
plates provide information on bearings, for instance:
• Type of grease used
• Re-lubrication interval
• Amount used for re-lubrication

[Link] Types of Grease

The manufacturer stipulates the use of the following greases:
1. Exxon Mobil Unirex N3 (lithium complex base)
2. Klüber Klüberplex BEM 41-141
See the rating plate on the generator for the correct amount of grease and re-lubrication
intervals.

[Link] Roller Bearing Grease for Extreme Temperature

If the bearing operating temperature is continuously:
• above 75 °C (167 °F)
• below 0 °C (32 °F)
Ask the manufacturer about suitable greases.

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[Link] Re-lubrication
CAUTION
Grease can cause skin irritation and eye infections.
Avoid physical contact with the hands by wearing disposable gloves.
Pay attention to all the safety measures stated by the grease manufacturer.

All roller bearings on rotating electrical machines must be regularly re-lubricated, see rating
plate. The lubrication can be either manual or with the aid of an automatic system. In both
cases make sure that an adequate amount of the correct lubricant reaches the bearing at
the stipulated intervals.
Manual re-lubrication of the bearings
Generators that are designed for manual lubrication are fitted with grease nipples. To ensure
that no dirt enters the bearings, clean the grease nipples and their surrounding area
thoroughly before lubrication.
Only re-lubricate with the generator running!
Re-lubrication is always done at the generator nominal speed. Re-lubrication at standstill is
not allowed, as the grease will not be correctly distributed in the bearing. The grease takes
the path of least resistance to the opposite side of the bearing. At standstill this means that
the grease cannot flow out of the bearing chamber and the replacement of the old grease is
not ensured.

[Link] Lubricating at Load

The load state of the generator is not of significance during re-lubrication. Re-lubrication
must be performed at the predominant related operating state on reaching the time for re-
lubrication, whether full load or half load. It is important that the re-lubrication intervals are
met and also documented.

[Link] Re-lubricating with Generator Running

WARNING
Rotating parts will shock or can cause loss of limbs or death.
During lubrication open long hair, loose clothing, and jewelry or similar can become
entangled in rotating components and be drawn in.
Very serious injuries can result. Wear PPE.

Do not stand behind the generator for the first 10 hours after [Link]-lubrication can
be done in various ways. The grease can be applied to the bearing in one pass or in several
stages. The important aspects are the duration of the re-lubrication process and the order.
The re-lubrication of a bearing should not be completed in less than 5 minutes, and should
also not take more than 30 minutes. The total amount of grease for the re-lubrication must
not be exceeded or dropped below in any circumstances. The manufacturer recommends
the use of suitable instruments to measure the amount of grease.
For the order in which the bearings are to be lubricated the combination of fixed, loose, fixed
bearing is to be followed.
1. Clean the grease nipple and its surrounding area
2. Make sure that you use grease as per the rating plate
3. Measure (weight or volume) the amount of grease that is pressed in during one stroke
4. Make sure the lubrication pipes are intact

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5. Press the stated amount of the type of grease stated into the bearing in the order stated
above while following the requirements on the time taken
6. Leave the generator to run for 1-2 hours to make sure the old excess grease is pressed
out of the bearing. The bearing temperature may increase temporarily during this time.

FIGURE 19. TEMPERATURE CURVE DURING RE-LUBRICATION

Engineers contracted by the manufacturer may act otherwise than stated in this section.
They will decide on site, depending on the condition of the generator and the ambient
conditions, how to re-lubricate. The actions done by the service engineers must not be
transferred to other generators or be considered general instructions.

[Link] Automatic Re-lubrication

Numerous automatic lubrication systems are available on the market. However, we only
recommend the use of electromechanical lubrication systems. The quality of the grease
entering the bearing is to be checked at least once a year. The grease must be free of
contamination and good in use. Do not use the grease after the shelf-life stated by the
grease manufacturer. The separation of the base oil from the soap is not acceptable.
If an automatic lubrication system is to be used, consult the manufacturer and the lubrication
system manufacturer about the lubrication interval and the amount of grease.

[Link] Shortage of lubricant

A shortage of lubricant occurs:
• if the correct amounts of grease are not in the bearing.
• if the correct amounts of grease are not in the grease reservoir.
• if the bearing is not re-lubricated at the stipulated intervals using the correct amount of
grease.
• if the oil is separated from the grease.

[Link] Grease Miscibility

Do not mix different types of greases together. The mixing of greases with different
thickeners can change the characteristic and physical properties of the grease. Even with
thickeners of the same type as a rule there will be differences in the additives with effects on
the performance of the grease that can only be determined by checking the roller bearing.

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The usage of non-compatible greases leads to bearing damages.

[Link] Incorrect Grease

Using the wrong lubricating greases results in the premature failure of the generator
bearings and cause other damage.

[Link] Lubricant Pressure During Re-lubrication

When grease is pressed into the grease reservoir and into the bearing during re-lubrication,
the pressures will change in the lubrication system. If the grease has been pressed into the
grease reservoir during re-lubrication more quickly than the old grease flows out on the
opposite side, the pressure on the bearing cover will further increase. With the generator
running the grease is now heated and expands. This also results in additional pressure
being required for re-greasing the lubrication system.
Pressure too high
If you notice a significant pressure increase during re-lubrication (more force required for re-
greasing than usual), check the lubrication system for:
• Unhindered discharge of the old grease
• Kinked or clogged fresh grease lines
• Leaks between shaft and bearing cover
• Leaks between bearing cover and bearing chamber
• Correct function of the grease nipple
• Intact grease gun
• Also check all screw fasteners and the bearing covers. Make sure to remove any
discharged grease.
Pressure too low
If you notice a significant pressure decrease during re-lubrication (less force required for re-
greasing than usual), check the lubrication system for:
• Leaks between shaft and bearing cover
• Intact fresh grease lines (e.g. broken or burst line)
• Correct function of the grease nipple
• Intact grease gun
• Also check all screw joints and the bearing covers. Make sure that any grease
discharged is removed.

[Link] Temperature Increase due to Re-lubrication

The temperature increase in the bearing during or after re-lubrication is the consequence of
the increased working of the grease as long as the currently increased amount of grease in
the bearing has not been distributed. (See Figure 19 on page 80.)
In a roller bearing with an adequate amount of lubricant, only a small amount of the lubricant
is used for building up the lubricating film, not the total amount. Some of the lubricant is
sprayed away, and some forms a lubricant flow in front of the rolling element/raceway
contact zone.
This temperature increase settles to around the value before re-lubrication after the
distribution of the grease.

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An elevated temperature in the bearings can exist for up to 96 hours. During this period
significant temperature increases can be seen (see Section [Link] on page 79). An
increase in the temperature is helpful for the lubricant change, as the old grease becomes
softer and can escape better from the bearing. Finally, the increase in the temperature is a
good indicator that the lubricant has actually reached the bearing.
When the temperature increases due to re-lubrication it is important that the warning and
shutdown temperatures stipulated by the manufacturer are met.

[Link] Influence of the Grease Level

With the required amount of grease for re-lubrication, freshly filled bearings have a
temperature significantly above the value before re-lubrication for operation hours up to
days. The cause of this phenomenon is explained in Section [Link] on page 81. After
the first re-lubrication the grease reservoir in the bearing cover is completely filled, this
increases the time required for the bearing temperature to drop again.

[Link] Grease Contamination

The more contaminants (water, dirt, fibers, metallic abraded material, etc.) found in the
grease, the more the properties of the grease will be degraded. Unlike oil lubrication, in
which contaminants can be filtered out, contamination can only be removed from the roller
bearing lubricant by prompt re-lubrication using fresh grease. The greatest risk is
contamination with hard particles that can cause surface damage to the bearing raceways
and finally premature bearing failure.
Grease contamination will result in the premature failure of the bearing.

[Link] Grease Hardening

Grease hardening will result in the premature failure of the bearing.
As a rule, grease hardening is caused by the absorption of dirt and moisture or due to
oxidation of the grease constituents over a long period of time. A long storage time or period
of generator standstill can cause grease hardening (refer to Section 5.2 on page 19).
During this process the base oil separates from the thickener. So-called grease "bleeding"
occurs.

[Link] Handling Bearings During Replacement

The bearings have a shorter service life than the generator itself. They therefore need to be
replaced from time to time.
• Do not fill a bearing with too much lubricant. The bearing may be damaged as a result.
Do not mix different types of lubricant. Change your gloves before handling a different
type of lubricant.
• Do not assemble bearings in statically charged environments. Pay attention to a dust-
free environment and wear lint-free gloves during assembly.
• Store removed parts and tools in environments that are not statically charged and that
are free of dust to prevent damage or soiling.
• A bearing will be damaged by the axial force that needs to be applied to remove it from
the rotor shaft. Once removed, a bearing cannot be re-used.
• A bearing will be damaged by the application of force to the rolling element. Do not use
force to fit any bearing components.
• Do not try to rotate the rotor by applying a lever to the fan blades. The fan will be
damaged as a result.
The servicing of roller bearings requires particular care, special tools and proper preparation
to ensure the newly fitted bearings have a long service life.

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During the servicing of the bearings, make sure that:

• At no time dirt or foreign bodies can enter the bearing during the servicing,
• The bearings and the rotor are not damaged during dismantling and assembly.
Removal requires the use of pullers or heat, installation is done with the aid of heat or
special tools.
If you are uncertain during the replacement of the bearings, contact the manufacturer.

10.7 Generators with Bearing Insulation

The insulation resistance test on the bearings is performed in the factory. The insulation is
neccessary to avoid bearing currents which result in bearing damages. The insulation at one
of the bearings interrupts the path of the current. Both ends of the shaft must not be
insulated from the housing without further measures. The standard is that the NDE bearing
is insulated.

10.7.1 Bearing Insulation on Roller Bearings

The bearing insulation is fitted in the bearing chamber. Check the integrity of the bearing
insulation, the bearing chamber and the surrounding bearing plate regularly. A bearing
insulation measurement is not possible with the generator assembled. It is necessary to
remove the uninsulated bearing from the generator.
Check the bearing insulation when each bearing is replaced.
Remove any shaft grounding brushes, rotor grounding brushes and coupling (if they are
made of conductive material) for the insulation test. Measure the insulation resistance
between the shaft and ground using 500 V DC as a maximum. The minimum insulation
resistance is 10 kΩ.

10.8 Service Windings

10.8.1 Safety Instructions for Servicing Windings
Hazardous servicing tasks on windings include:

WARNING
Hazardous voltage will shock, burn or can cause death.
Tests at high voltage (HV) must only be done by authorized specialist personnel following the
related safety regulations.

CAUTION
Danger of chemical burn and poisonous vapors will chemically burn or burn or cause
suffocation.
Flammable and hazardous substances like solvents, resins and lacquers must be handled
and used by authorized specialist personnel only while following the related safety
regulations and instructions. These substances must not be inhaled or swallowed or come
into contact with the skin or other organs. Seek medical attention immediately in case of an
accident.
Take the necessary precautions if you are working in pits or poorly accessible / poorly
ventilated areas. Do not smoke or eat in the workplace. Wear PPE.

For spray lacquering, ensure that the lacquering equipment, the generator frame and the
windings are earthed.
Solvents, lacquers and resins are required to clean and re-lacquer the windings.

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10.8.2 Scheduling the Servicing

As a guideline the insulation resistance test should be done once a year. This rule is
sufficient for the majority of generators under the majority of operating conditions. Additional
tests must be performed if problems occur.
You will find a servicing schedule for the complete generator including the windings in
Section 10.3 on page 66. This servicing schedule should be adapted to the specific
circumstances at the customer, in the context of the recommended servicing intervals, i.e. to
the servicing of other machines and the general operating conditions.

10.8.3 Correct Operating Temperature of Windings

Ensure the correct temperature of the windings:
• by keeping the external surfaces of the generator clean.
• by checking the cooling system for correct operation.
• by monitoring the temperature of the coolant.
If the coolant is too cold, water may condense inside the generator and the winding
becomes damp, resulting in a degradation of the insulation resistance.
For air-cooled generators it is important to monitor the cleanliness of any air filter fitted. The
air filter cleaning and replacement interval is to be planned and implemented to suit the local
operating environment. Increased winding temperatures can be indicative of a clogged air
filter.
The operating temperature of the stator must be monitored using temperature sensors.
Large differences between the values from the sensors can be indicative of damage to the
windings.

10.8.4 Insulation Resistance Test

Measure the insulation resistance of the stator and rotor windings During the general
servicing work , before the generator is started for the first time or after extended standstill.
The insulation resistance value provides information on the moisture and soiling of the
insulation.
For new generators with dry windings, the insulation resistance is very high. However it can
be very low if the generator is subjected to incorrect transport, storage conditions and
moisture, or is operated incorrectly.
• If the measured value is under the rated voltage in kV + 1 MOhm, the windings must be
cleaned and/or dried. If these measures are insufficient, consult the manufacturer.
• If a moisture problem is suspected, dry the insulation before the resistance is
measured.
• The insulation resistance will reduce with increasing winding temperature.
The insulation resistance stated in the test report is normally higher than that measured at
site.

[Link] Windings Criteria in Normal Condition

The insulation resistance on dry windings should significantly exceed the minimum values.
The insulation resistance is dependent on the age and the use of the generator.
Typically, in test field measured insulation resistance values at approx. 25 °C winding
temperature:
Rated voltage 3.3 kV up to 1.5 kV: > 1000 MOhm

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Rated voltage 380 V up to 1000 V: ≥ 400 MOhm

Main rotor ≥ 300 MOhm
Exciter stator ≥ 50 MOhm
PT100 & anti-cond. heater ≥ 50 MOhm
A low resistance is often caused by excessive moisture or by dirt, even though the actual
insulation is intact.

[Link] Insulation Resistance Measurement on the Stator Windings

DANGER
Hazardous voltage will shock, burn or cause death.
The windings are to be grounded immediately after the measurement to avoid the risk of
electric shock.

The insulation resistance is measured using an insulation resistance tester. Before

undertaking the tests, take the following precautions:
1. Make sure that all power supply cables are disconnected from the main power supply
and secured against unintentional switching back on.
2. Check the tester for correct function.
3. Make sure the secondary connections on the current transformer including the
replacement core are not open.
4. Make sure all power supply cables are disconnected.
5. Make sure the stator and the stator windings as well as the auxiliary exciter stator,
exciter stator and any auxiliary windings that are not tested are grounded.
6. Measure the winding temperature on the PT100 of the stator.
7. Ground all resistive temperature sensors
8. Remove any grounding in the voltage transformer.
9. Ground all Rotor cables and exciter rotor cables as well as auxiliary windings.
Measure the insulation resistance measurement in the terminal box. The test is normally
done on the entire winding as an assembly; connect the tester between the stator housing
and the winding. Ground the stator and leave the three phases of the stator winding
connected to the star point. If the insulation resistance measured in the entire winding is
lower than stated and the phase windings can be easily disconnected from each other,
measure each phase separately. This action is not possible on all generators. To measure
separately, connect the tester between the stator and one of the windings. Ground the stator
and the two phases not measured.
If phases are measured separately, remove all star points in the winding system.

[Link] Insulation Resistance Measurement on the Rotor Winding

DANGER
Hazardous voltage will shock, burn or cause death.
The windings are to be grounded immediately after the measurement for a period equal to the
duration of the measurement of the insulation resistance to avoid the risk of electric shock.

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Measure the insulation resistance on the rotor winding using an insulation resistance tester.
The test voltage for the rotor windings should be 1000 VDC.
1. Make sure that all power supply cables are disconnected from the main power supply
and secured against unintentional switching back on.
2. Check the tester for correct function.
3. Make sure the generator and the stator windings as well as the temperature monitoring,
auxiliary winding, auxiliary exciter stator, exciter stator are grounded.
4. Make sure the shaft is grounded.
5. During the insulation resistance measurement in the exciter rotor the rotor windings not
tested must be grounded. The rotor winding can be connected internally in series or 2
groups connected in parallel.
6. Measure the rotor winding temperatures. If this is not possible, use the stator winding
temperatures as a reference.
7. Connect the insulation resistance tester between the entire rotor winding and the shaft.
After the measurement, the rotor winding must be grounded for at least as long as the
duration of the measurement to discharge the winding.

[Link] Other Servicing Work on the Windings

Windings are normally trouble-free and only require occasional cleaning and drying in
addition to the regular monitoring described above. If unusual conditions make additional
servicing work necessary, seek the advice of the manufacturer.

10.8.5 Insulation Resistance Measurement for Ancillary

Equipment
The test voltage for the anti-condensation heater must be 500 VDC.
Do not measure the insulation resistance of Pt-100 sensors.
To ensure the correct operation of the generator and its ancillary equipment, refer to the
documentation in the Appendix.

10.8.6 The Polarization Index

For the polarization index test the insulation resistance is measured after the test voltage
has been applied for 1 minute and 10 minutes. The polarization index depends less on the
temperature than on the insulation resistance. If the winding temperature is below 50 °C
(122 °F), it can be considered independent of temperature. High temperatures can cause
unforeseen changes in the polarization index, for this reason use above 50 °C (122 °F) is
not to be recommended.
Dirt and moisture in the windings will normally reduce the insulation resistance and the
polarization index as well as their temperature dependence.
There are several rules for determining the lowest acceptable value at which the generator
can be safely started.
The minimum PI value for stator windings of class F is 2.
If the insulation resistance of the windings is in the area of several thousand MΩ, the
polarization index does not represent a clear criterion for the condition of the insulation and
can be ignored.

86 A046V044 (Issue 1)
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10.8.7 Servicing the Grounding Brushes

DANGER
Hazardous voltages, rotating parts and hot surfaces will shock, burn or cause loss of limbs
or death.
Only undertake servicing work with the generator at standstill.

Optimal servicing and care of the brushes and slip rings is a prerequisite for low wear. The
brushes must be cleaned from time to time by blowing with air or vacuum cleaning.
• The servicing must be done at specific intervals. The frequency of this servicing
depends on the size of the generator as well as on the load conditions and ambient
conditions.
It is recommended to initially check the brushes every three months to be able to estimate
the replacement intervals under the actual operating conditions. Replace only with approved
brushes.
• Check all brushes and holders for freedom of movement. Sticking brushes can result in
damage.
• Renew worn brushes in good time so that damage to the brush contact surfaces is
avoided.

No. Description No Description

1 Brush holder with ground connection and 3 Carbon Brush
removable carbon brush spring
2 Brush pin

[Link] Ground Fault Monitoring

DANGER
Hazardous voltages, rotating parts and hot surfaces will shock, burn or cause loss of limbs
or death.
Only undertake servicing work with the generator at standstill.

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10. Service and Maintenance 6-2013

No. Description No Description

1 Brush holder with connection 3 Carbon Brush
2 Brush pin 4 Slip Rings

FIGURE 20. GROUND FAULT MONITORING

• Renew Worn carbon brushes in good time so that damage to the slip rings is avoided
and the correct function of the ground fault monitoring is ensured.
Open the spring and replace the old carbon brushes with the new ones.
• New brushes must bed in on the slip rings.
Replace only with approved brushes. The ground fault monitoring is installed on the non-
drive side of the generator.

10.9 Servicing the Generator Cooling

Check the generator cooling regularly to ensure trouble-free operation.

10.9.1 Servicing Instructions for Generators with Open-circuit

Ventilation
The cooling airflow is normally provided by a fan mounted on the rotor. The cooling air must
be clean and dry, as dirt and/or moisture entering the generator reduces the cooling
performance.
The generator can be equipped with temperature sensors for monitoring the internal cooling
air. As long as the temperature sensors indicate a temperature within the specified limits, no
servicing other than regular inspection of the generator is necessary.
Check the cooling system if the temperature sensors indicate an abnormal winding or
cooling air temperature or a temperature near the alarm limit.
Possible causes of high cooling air temperature are:
• Waste heat from Malfunctions in the lubrication system or excessively high bearing
temperatures.
• The minimum distances between the cooling air inlet and neighboring components are
not maintained.
• The outlet air is drawn in with the inlet air.
• Defective temperature measuring instruments.

NOTICE
To avoid any material damage ensure that the distance between the air inlet (AI) or air outlet
(AO) on the generator and a wall or another plant component is at least a minimum of 500
mm. Unhindered AI and AO must be ensured.

88 A046V044 (Issue 1)
6-2013 10. Service and Maintenance

10.9.2 Service Instructions for Generators with Air Filters

The servicing must be done at specific intervals. The frequency of this servicing depends on
the size of the generator as well as on the operation and ambient conditions.
The filter frame and the filter mats are made of:
Stainless steel with round stainless steel wire mesh fabric depending on the application
conditions
Filter class:
EU2 in accordance with DIN 24185 / part 2
Medium filtration efficiency 65 ≤ 80%
• The servicing intervals are to be adapted to the local dust conditions.
Check the filter initially every three months to estimate the cleaning intervals under the
actual operating conditions.

[Link] Cleaning the Air Filter

NOTICE
Remove the filter mats from the generator for cleaning. Do not spray inside the generator
using a high-pressure cleaner.

Regular servicing and cleaning of the dust protection filter system is essential for the reliable
operation of the generator.
Do not wet filter mats using oil! Pay attention to environmental obligations!
Soiling such as salt, oil, fumes, chemicals, dust, sand etc. will reduce the efficiency of the
insulation and result in premature failure of the windings.
Therefore it is necessary to clean the filters regularly. If the temperature sensors in the
winding indicate an abnormal temperature close to the alarm level, the filters must be
cleaned.
If a monitoring system for the filter differential pressure is used, replace the filters in case of
a pressure alarm. The alarm is triggered if 50% of the air filter surface is clogged. Check the
filter manually on a frequent basis.
For cleaning the filter with cleaning agent the following applies:
• Commercially available cleaning agents can be used for mechanized cleaning or
cleaning using a high-pressure cleaner. The cleaning agent must be compatible with
the materials.
• If only manual cleaning is possible, use Repoint / RG 1083 or equivalent.

10.9.3 Servicing Instructions for Generators with Heat

Exchangers
Over time soiling on the cooling surface and the pipes wall reduce the cooling performance.
Clean the heat exchanger at regular intervals according to local conditions. Check the heat
exchanger frequently during the initial operating period.
Clean the heat exchanger using compressed air or clean it using a soft round brass brush.
Do not used steel brushes in or on aluminum pipes, a these pipes may be damaged.

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10. Service and Maintenance 6-2013

[Link] Air-water Heat Exchanger

If the temperature sensors indicate a normal operating temperature and the leak detectors
are not indicating any leak, visual inspection of the generator at a servicing interval is
sufficient. See also Section 10.9.1 on page 88.
For information on servicing the heat exchanger, see documentation from the manufacturer
in the Appendix.

[Link] Air-air Heat Exchanger

Visual inspection at a servicing interval is sufficient.
See also Section 10.9.1 on page 88.
For information on servicing the heat exchanger, see documentation from the manufacturer
in the Appendix.

[Link] Servicing External Fan Motors

The fan motor is serviced as per the documentation from the fan manufacturer.
It is recommended to keep a spare fan motor in stock.

10.10 Repairs, Dismantling and Re-assembly

NOTICE
Incorrect handling, repair, dismantling and re-assembly will result in serious damage.

All work related to repair, dismantling and re-assembly must be done by specially trained
personnel.

90 A046V044 (Issue 1)
11 Fault Finding
DANGER
Hazardous voltage.
Will shock, burn or cause death.
Fault finding methods include tests on live electrical conductors carrying high voltage. Risk
of serious injury or death by electric shock. Fault finding must be done by competent,
qualified persons trained in safe working practices.
Assess risk and work on or near live conductors only if absolutely necessary. Do not work on
or near live conductors alone; another competent person must be present, trained to isolate
energy sources and take action in an emergency.
Place warnings and prevent access to test area by unauthorised persons.
Make sure that tools, test instruments, leads and attachments are designed, inspected and
maintained for use on the maximum voltages likely under normal and fault conditions.
Take suitable precautions to prevent contact with live conductors, including personal
protective equipment (PPE), insulation, barriers and insulated tools.

Before starting any fault finding procedure, examine all wiring for broken or loose
connections. If in doubt, refer to the wiring diagram supplied with the generator. Compare
measurements with the test report supplied with the generator.
The following list is to aid in troubleshooting and is not exhaustive. If in doubt, consult the
Cummins service department.

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11. Fault Finding 6-2013

11.1 Generator, General

SYMPTOM POSSIBLE CAUSE MEASURE
Vibration Noise Malfunction in the lubrication Check quality and quantity of
system lubricant as well as system
function
Malfunction in the Check condition of the bearing,
bearing/bearing components replace faulty parts
damaged
Malfunction in the Open and correct adjustments
bearing/bearing fitted incorrectly
after replacement
Malfunction in the cooling Check fan, clean, replace in
fan/imbalance/damage on the case of damage and identify
fan cause
Displacement of the machine Check and make sure correct
alignment of the machine
Imbalance on rotor/shaft or Check imbalance and re-
coupling balance
Vibration on the prime mover Check type of coupling, check
foundation, check decoupling of
the attachments from the unit
Axial load Check alignment as well as
coupling function and coupling
type
Coupling fitted incorrectly Check and make sure correct
coupling assembly
Excessive line asymmetry Ensure compliance with the line
symmetry requirements
Loose part Repair, replace or re-fasten if
necessary
Damaged parts Identify and correct the cause
and replace damaged parts
Noise Loose parts Repair, replace or re-fasten if
necessary
Electrical noises Check stator, rotor
Malfunction in the cooling Check cooling system, clean
system and repair as necessary
Foreign bodies, moisture or dirt Check the interior of the
in the machine generator for damage and
clean, dry the windings, remove
foreign bodies
Vibration Inadequate, damaged Check foundation in consultation
foundation with the manufacturer of the unit
and Cummins
Tilting foot, fastening of the Check fastening and re-align
generator inadequate

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11.2 Lubrication System and Roller Bearings

SYMPTOM POSSIBLE CAUSE MEASURE
High bearing temperature Inadequate lubrication Check bearings, check amount
of grease in the bearing and re-
lubricate, follow manufacturer's
grease recommendations,
High bearing temperature, Inadequate lubrication Check grease line system for
grease in the machine leaks, check re-lubrication
intervals
High bearing temperature, Excessive lubrication Check bearings, check amount
grease in the machine of grease in the bearing and
reduce, follow manufacturer's
grease recommendations
High bearing temperature Axial/radial load Check coupling, installation and
excessive/coupling and alignment
installation defects
High bearing temperature Machine displacement Re-align machine
High bearing temperature, Grease outlet blocked Clean grease outlet,
grease in the machine
High bearing temperature, Bearings fitted incorrectly after Check installation of the
bearing noise or vibration replacement bearings and attachments
Quality of grease Check bearings, check re-
degraded/incorrect re-lubrication lubrication log, quality of grease,
interval type of grease
Bearing currents Check bearing insulation, repair,
replace bearing if necessary
Bearing damaged/failure of the Replace faulty bearing parts
bearing
Bearing damaged/normal wear Replace bearing
Bearing noise or vibration, Foreign body in the bearing Correct cause, replace bearing
visible damage and check condition of the seal,
attachments
Grease leaks, grease in the Line system faulty, grease outlet Correct cause, clean grease
machine malfunction outlet and generator
High bearing temperature Instrument fault/temperature Check bearing temperature
sensor faulty monitoring system
Grease leaks Bearing seals damaged or worn Replace bearing seals
High bearing temperature Lubrication system malfunction Check re-lubrication intervals,
quantity and if grease has
hardened
Grease leaks External vacuum/rotating Check pressures, change
equipment in the vicinity position of the rotating
equipment

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11. Fault Finding 6-2013

11.3 Open Cooling System

SYMPTOM POSSIBLE CAUSE MEASURE
High winding temperature, High inlet air Change air management
high cooling air temperature temperature/ambient air too hot
High inlet air temperature/outlet Change air management,
air is drawn in again ensure adequate space around
the machine,
High inlet air temperature/heat Remove or re-position heat
source in the vicinity sources, check ventilation
Inadequate air flow/machine Clean generator parts and air
interior soiled gaps
Inadequate air flow/air ducts Check condition of the air duct,
incorrectly arranged correct installation defects
Inadequate air flow/inlet Clean deposits from inlet
openings blocked openings
Inadequate air flow/air filter Clean or replace air filters
clogged
Fan damaged Replace fan
Incorrect speed, direction of Adjust speed, direction to the
rotation manufacturer's specifications
Instrumentation or measuring Check measurements, sensors
system defect and wiring
High winding temperature Overload/control system settings Check generator control system,
remove overload
Line asymmetry Ensure compliance with the line
symmetry requirements
Winding damage Check windings
Reactive load outside the Correct cause
specifications

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11.4 Air-air Cooling System

SYMPTOM POSSIBLE CAUSE MEASURE
High winding temperature, Drop in the performance of the Replace fan
high cooling air temperature main cooling system/fan
damaged
Drop in the performance of the Replace fan
main cooling system/fan is
rotating in the wrong direction
Drop in the performance of the Correct cause of the soiling,
main cooling system/interior of clean generator parts and air
the machine soiled gaps
Drop in the performance of the Repair or replace fan
secondary cooling
system/external fan damaged
Drop in the performance of the Correct direction of rotation of
secondary cooling system/fan is the external fan
rotating in the wrong direction
Drop in the performance of the Repair cooler
secondary cooling system/cooler
leaking
High inlet temperature/ambient Change air management
air too hot
High inlet temperature/outlet air Ensure adequate space around
is drawn in again the generator
High inlet temperature/heat Remove or re-position heat
sources in the vicinity sources, check ventilation
Incorrect speed, direction of Adjust speed, direction to the
rotation manufacturer's specifications
Instrumentation or measuring Check measurements, sensors
system defect and wiring
High winding temperature Overload/control system settings Check generator control system,
remove overload
Line asymmetry Ensure compliance with the line
symmetry requirements
Excessively frequent starts Leave machine to cool down
before the start
Winding damage Check windings
Reactive load outside the Correct cause
specifications

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11. Fault Finding 6-2013

11.5 Air-water Cooling System

SYMPTOM POSSIBLE CAUSE MEASURE
High winding temperature, Drop in the performance of the Replace cooler
high cooling air temperature, secondary cooling system/leak
water leak alarm in the cooler
Instrumentation or measuring Check measurements, sensors
system defect and wiring
High winding temperature, Drop in the performance of the Check fan, cooling circuit
high cooling air temperature, main cooling system/fan
damaged
Incorrect direction of fan Replace fan
rotation
Drop in the performance of the Correct cause of the soiling,
main cooling system/interior of clean generator parts and air
the machine soiled gaps
Drop in the performance of the Open cooler and clean pipes
secondary cooling
system/coolant pipes blocked
Drop in the performance of the Check pump and repair
secondary cooling
system/coolant pump faulty
Drop in the performance of the Check coolant flow and adjust
secondary cooling correctly
system/incorrect flow rate
adjustment
Drop in the performance of the Bleed cooler
secondary cooling system/air in
the cooler
Drop in the performance of the Securely close emergency
secondary cooling ventilation flap
system/emergency ventilation
flap open
Cooling water inlet temperature Adjust cooling water
too high temperature correctly
High winding temperature Overload/control system settings Check generator control system,
remove overload
Line asymmetry Ensure compliance with the line
symmetry requirements
Excessively frequent starts Leave machine to cool down
before the start
Winding damage Check windings
Reactive load outside the Correct cause
specifications

In case of high bearing temperatures, see Section 10.6 on page 78

96 A046V044 (Issue 1)
6-2013 11. Fault Finding

11.6 Faults on the Brushes

SYMPTOM POSSIBLE CAUSE MEASURE
Brushes not working correctly Brushes are worn Replace the brushes and check
the surface of the shaft
Brushes are sticking in the Loosen the brushes, check the
holders size and if necessary replace
the brushes
Brushes are excessively loose If brushes are worn out or are
in the holders too small, replace
Wrong size, check the size and
replace
Loose connection at the brush Tighten the connection
terminals
Incorrect bedding in of the Replace the brushes
brushes
Incorrect and uneven brush Re-adjust the holder of the
pressure brushes
Mating faces on the slip rings Clean and if necessary replace
worn or soiled the slip ring and the brushes
Type of carbon brushes is not Operate the generator only
suitable for the operating according to the rating plate.
conditions Consult Cummins service
department regarding the
operating conditions.
Imbalance in the generator Arrange for re-balancing of the
generator by specially trained
personnel only
Uneven air gaps as a result of Check the bearing and replace
worn bearings. the bearing if necessary

11.7 Electrical Power, Excitation, Control and

Protection
The electrical power output of a generator is determined primarily by the condition of the
rotor and stator windings and secondly, by the operation of the excitation system. The main
servicing of the generator winding is described in Section 10.8 on page 83. This section
concentrates on troubleshooting the excitation, control and protective system.

11.7.1 Triggering the Protective System

The generator must be protected with alarm and shutdown functions for abnormal electrical
or mechanical operating conditions.
Investigate the following events if they trigger an alarm or a protective system:
• Diode failure
• High bearing temperature,
• High temperature in the windings or the cooling air
• Failure of the isolating or matching transformer
• Vibration protection (if fitted)

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11. Fault Finding 6-2013

11.7.2 PT-100 Resistive Temperature Sensors

PT-100 resistive temperature sensors are a significant element of the monitoring and
protective system for the generator. They are used to measure the temperature in the stator
windings, in the bearings and in the cooling air. The sensors can be damaged by incorrect
handling or excessive vibration.
The following symptoms can be indicative of a problem in a Pt-100 sensor:
• Infinite resistance or zero resistance in the PT-100 sensor
• Loss of the measured signal during or after switching on
• A significant difference in the resistance of an individual sensor to the other sensors
If you suspect that a PT-100 has failed, check the connection in the terminal box by
measuring the resistance at the PT-100 sensor with the cables disconnected.
If a PT100 in the stator is defect, use the spare one. All other defective PT100 sensors can
be replaced.

11.8 Thermal Performance and Cooling System

Unusual generator temperatures rises are caused by the following reasons:
• The efficiency of the cooling system has dropped and the heat of the generator can not
dissipate
• The generator itself is generating an excessive amount of heat.
If the temperature of the generator exceeds the normal values, measures must be taken to
determine the reason.
Excessive heat production can be caused by damage to the winding, excessive loading or
line asymmetry; in these cases corrective measures on the cooling system are ineffective or
will cause damage. If you suspect that the efficiency of the cooling system has dropped or
the cooling air temperature sensors are indicating an abnormally high temperature, check
the cooling system. Check the following:
• Ensure the air circulation is uninterrupted and free of faults
• For heat exchangers, ensure reliability by means of regular cleaning and function
checks.
• Check the air or water flow through the heat exchanger. If the cooler is equipped with
an external fan, check its function.
Other causes of an abnormally high temperature are:
• Elevated ambient temperature
• High air or water inlet temperature
• Low air or water flow rate
In addition, malfunctions in the lubrication system or the bearings will result in excessively
high bearing temperatures and therefore more heat in the cooling system.
An apparently high temperature can also be caused by a problem with the temperature
sensors.

98 A046V044 (Issue 1)
12 Spares and After Sales Service
We recommend the use of genuine STAMFORD service parts supplied from an authorised
service outlet. For details of your nearest service outlet visit [Link].
Aftermarket Help Desk
Phone: +44 (0) 1780 484744
Email: [Link]@[Link]

12.1 Customer Service

You can contact customer service at:
Cummins Generator Technologies
Bunsenstr. 17
85053 Ingolstadt, Germany
Tel. no.: +49 0841 / 792-0
Fax no.: +49 841 / 792 250

12.1.1 Spare Parts

The spare parts department sells genuine spare parts for generators supplied.
You can contact our spare parts department at:
Cummins Generator Technologies
Bunsenstr. 17
85053 Ingolstadt, Germany
Tel. no.: +49 0841 / 792-192
Fax no.: +49 0841 / 792 238

12.1.2 Customer Service and Warranty

The service department will handle warranty claims. Claims must be notified in writing during
the warranty period.
This department will:
• Decide on warranty claims
• Decide on corrective measures
• Provide technical support within the warranty period

12.1.3 Important Information

Always state the serial number given on the rating plate for quick processing.

A046V044 (Issue 1) 99
12. Spares and After Sales Service 6-2013

12.2 Spare Parts for Generators

12.2.1 General Information on the Spare Parts
The generators manufactured by Cummins are designed and built for reliable, trouble-free
operation. However, a precondition for their freedom from malfunctions is correct servicing
and operation. This servicing includes the replacement of parts subject to normal wear.
The amount of wear cannot be predicted with absolute accuracy. The wear rates on the
individual components vary widely depending on the application, environment and specific
conditions. For this reason check the condition of these parts regularly and keep an
adequate number of spare parts in stock. These spare parts will help to minimize the
downtime if they are required. Decide the scope of the parts held in stock based on the
importance of the application, the availability of the related spare part and the experience of
the local maintenance personnel.

12.2.2 Regular Parts Replacement

Replacement of parts due to normal wear or due to incorrect operation is excluded from the
warranty. If two moving surfaces are in contact, they will wear over time. For generators, the
major mechanical wear occurs between the rotating shaft and the fixed parts. The bearing
parts, e.g. the roller bearings or the bearing shells and oil lubrication rings in plain bearings,
wear over time and must be replaced occasionally despite correct lubrication. Other wearing
parts are seals, brushes and brush systems that are in continuous contact with the rotating
shaft.
The parts mentioned above do not represent a complete list of the mechanical wearing
parts. Their actual service life can vary significantly from the calculated service life as a
function of the actual operating conditions.

12.2.3 Spare Parts Required

Other types of wear occur due to elevated temperatures, electrical malfunctions and
chemical reactions. Wear on the diodes on the rectifier bridge is usually caused by abnormal
operating conditions. This is normally a slow process that is heavily dependent on the
generator operating conditions and system malfunctions.
The electrical windings have very good protection against wear, provided the servicing and
operating instructions are followed carefully. Do not exceed the correct operating
temperature and clean the windings regularly to remove dirt. Winding wear can also be a
consequence of electrical malfunctions.
In the stator slots there are PT100 temperature sensors for the stator windings; these
sensors cannot be replaced and are not available to order.

100 A046V044 (Issue 1)

13 End of Life Disposal
Companies specialising in reclaiming material from scrap products can reclaim most of the
iron, steel and copper from the generator. For more details, please contact Customer
Service.

13.1 Disposal
The large portion of iron, steel and copper in the generator can be recovered by specialist
recycling organizations. You can obtain further information from Cummins customer service.

13.2 Introduction
The following instructions are only recommendations for the environment-friendly disposal of
the generators. It is the responsibility of the operating organization to follow local regulations.
Some customer-specific elements may not be included in this user manual. This section
makes no claim to completeness.

13.3 Average Material Content

The average material content used during the manufacture of the generator is as follows:

Generators with cast iron Generators with welded

bearing plates bearing plates
Steel 46–55% 77–83%
Copper 7–12% 10–12%
Cast iron 35–45% 1–5%
Aluminum 0–2% 0–1%
Plastic, rubber, insulating 1–2% 1–2%
material etc.
Stainless steel Less than 1% Less than 1%
Others Less than 1% Less than 1%

Following materials are not used:

• Asbestos
• Polychlorinated Biphenyls
• CFCs
• Haloms
• Other fully halogenated CFCs
• Carbon Tetrachloride
• 1,1,1 Trichloroethane Methyl Chloroform
• Hydrochlorefluorocarbons
• Hydrobromofluerocarbons
• Methyl bromide
• Bromochloromethane

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13. End of Life Disposal 6-2013

• Tributyl Tins
• Triphenyl Tins
• Tributyl Tin Oxide (TBTO)
• Cadmium and Cadmium Compounds
• Hexavalent Chromium and Hexavalent Chromium Compounds
• Mercury and Mercury Compounds
• Polybrominated Biphenyl (PBBs)
• Polybrominated Dephenyl ethers (PDBEs)
• Polychloronsphthalanes (C1= <3)
• Radioactive Substances
• Certain Shortchain Chlorinated Paraffins

13.4 Recycling Packaging Material

After the generator has arrived at the operating organization, the packing material must be
disposed of.
• Wooden packaging can be recycled.
• Recycle the packaging for maritime transport made of impregnated wood in accordance
with local regulations.
• Do not burn the packaging made of impregnated wood.
• The plastic material wrapped around the generator can be recycled.
• Anti-corrosion agents that cover the surface of the generator can be cleaned using a
petrol-based cleaning agent and a cloth. The cloth is to be disposed of in accordance
with local regulations.
• Desiccants are to be disposed of in accordance with local regulations.

13.5 Dismantling the Generator

DANGER
Heavy loads.
Do not stand under suspended loads. The load may drop due to improper fastening or failure
of the lifting equipment and cause very serious injuries or death.
Secure transport routes.

The generator must be transported and unloaded by persons who are familiar with the lifting
equipment and related ancillary equipment. All lifting equipment and tackle must be suitable
for the weight of the generator and must comply with local regulations.
The safety regulations on handling the generator are to be followed at all times. The
generator is assembled with screws and can be dismantled. The high weight of the
generator requires the presence of specialist personnel trained in handling heavy
components to avoid hazardous situations.

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6-2013 13. End of Life Disposal

13.6 Separation of the Different Materials

13.6.1 Stator, Bearing Housing, Covers and Fans
These parts mostly comprise mild steel that can be recycled in accordance with local
regulations. All additional equipment, cables and bearings are to be removed before melting
down the material.

13.6.2 Components with Electrical Insulation

The stator and the rotor are the main components that contain electrical insulation materials.
Some additional components are, however, made of similar materials and are treated in a
similar manner. These components are:
• Insulators used in the terminal boxes
• The exciter rotor
• The exciter stator
• The voltage and current transformers
• Primary and secondary cables
• Overvoltage arresters
• Diodes and varistors
Not all these components are used in all generators. Components with electrical insulation
are in an inert and therefore non-reactive state after the manufacture of the generator. Some
components, in particular the stator and rotor, contain a significant copper content that can
be separated in a suitable heat treatment process by gasification of the organic binder
materials in the electrical insulation. To ensure the correct combustion of the vapors, the
furnace must have a suitable afterburner unit.

13.6.3 Hazardous Waste

The oil and grease from the lubrication system is hazardous waste and is to be disposed of
in accordance with local regulations.

13.6.4 Residual Waste

All insulation materials can be disposed of as residual waste.

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13. End of Life Disposal 6-2013

This page is intentionally blank.

104 A046V044 (Issue 1)

Bunsenstrasse 17
Inglostadt
Germany
Tel: +49 841 7920
Fax: +49 841 792XX
[Link]
Copyright 2013, Cummins Generator Technologies Ltd. All Rights
Reserved
Cummins and the Cummins logo are registered trademarks of Cummins
Inc.
Check list
Maintenance Work – Commissioning – Overhaul – Major Repair
AvK Checklist to Order No. Page 2

Customer: .............................................................

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

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

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

Bearing design: Roller bearing 

Sleeve bearing 

YES NO
Replacement of oil:  

YES NO
Bearing inspection performed:  

I. Electrical Inspection

Pos. 1.1 - 1.19

II. Mechanical Inspection

Pos. 2.1 - 2.20

III. Test Run

Pos. 3.1 - 3.14

IV. Maintenance Result

Cummins Generator Technologies Germany GmbH Page 2

[Link]
AvK Checklist to Order No. Page 3

Environmental Conditions (please take pictures):

a) Location: building  marine 

b) Atmosperic conditions: dry  high humidity 

dust  salt 

c) Ventilation: unrestricted  adequate 

restricted  inadequate 

Air intake needs to prevent dust and moisture is transported into the generator by external ventilation. In
case of doubt please contact the customer support.

Operating Conditions:

Please add the operation charts and diagrams showing electrical parameters and temperatures including
alarm.

a) Site duty: single  parallel  idle 

b) Duty cycle: 24 hours  daily  occasionally  standby 

c) Load condition: inductive  non linear 

d) Operation: manned  unmanned 

Generator Conditions:

a) Dirt content: slight dust  light layer dirt 

thick dust  thick compact dirt 

b) Corrosion: none, very little  steel/iron 

copper  severe  (....................)

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

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

Cummins Generator Technologies Germany GmbH Page 3

[Link]
AvK Checklist to Order No. Page 4

3.15 Inbuilt type of Automatic Voltage Regulator (AVR)

The regulating system has to be adjusted to the driving conditions and load at site for avoiding a swinging up
and assure an optimal regulation behaviour.

AVR serial number _______________

 Cosimat

Type of Cosimat: _______________

 Additional module: _______________

No-load voltage [V]: _______________

Droop [%]: _______________

Underfrequency protection [Hz]: _______________

 DECS 100

 DECS 200

 Unitrol

 Other: _______________

Additional module

 XE2

 SB2

 EDM

 Manual controller

 AVR system mounting plates with extra functions

 Standby AVR switchover system

 Other: _______________

Cummins Generator Technologies Germany GmbH Page 4

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Safety instructions:

Safety Regulations:
1. Disconnect mains!
2. Prevent reconnection!
3. Test for absence of harmful voltages!
4. Ground and short circuit!
5. Cover or close off nearby live parts!

To energize, apply in reverse order!

Only specially trained and experienced per sonell is allowed to perform work at the alternator.
Even small failures during work may result in damage of health or major machine failure.

Local safety rules have to be obser ved.

Caution!

The motor start function has to be blocked twice (Emergency stop & Power Supply Starter).
Before terminal box is opened, HV alternator has to be grounded in the switchboard.
This has to obser ved by the techni cian.
Alternator cables need to be proved to be without voltage.
After the terminal box is opened, the cables have to be proved to be without voltage again.

Never operate any alternator with open main terminal box!

General work Instructions:

All bolts and mechanical fixation should be checked visually and in case of any signs of looseness
or movement of fixed parts, the bolts need to be tightened.

Electric contacts, terminals, bolts and cable luggs have to be checked carefully for loseness,
discoloration and other signs of contact problem.
Check for cable chafing and fretting dust as a sign of material deterioration.

Windings need to be checked visually in addition to the measurements shown in the list below.
Any movement of windings, seen by cracks in the protection color – layer and discolorations of
windings need to be dokumented with digital pictures.

Digital pictures should show the installation, building, alternator name plate, internal parts and all
alternator parts which are found not to be in good functional order.

Cummins Generator Technologies Germany GmbH Page 5

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AvK Checklist to Order No. Page 6

I. Electrical Inspection

performed Complaints
see page 18

 1.1 Examination of cable entry and cable shoes 

to main terminal box

 1.2 Examination of strain relief of connecting power cables 

 1.3 Check of fixation of transformers installed 

 1.4 Examination of cable entry and cable shoes 

to auxiliary terminal box

 1.5 Check of strain relief of connection cables 

Incoming cables should be supported from either below or above the box level at a sufficient distance
from the centre line of the generating set so as to avoid a tight radius at the point of entry into the
terminal box panel, and allow movement of the generator set on its anti-vibration mountings without
excessive stress on the cable. The generator should be free to move at least ±25 mm as per Figure 1.
In addition refer to the operating instructions under point “Electrical connections”.
Please see also the AvK documentation about commissioning instructions.

Alternator movement during operation due to changing torque forces

Cummins Generator Technologies Germany GmbH Page 6

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Insulation measurement - Caution! -

The AVR plus any voltage transfor mer s should be disconnected, and any temperature detector leads
(RTDs / Thermistor s) grounded during the test. Refer to the generator wiring diagram for details.
After measurement discharge all windings and reconnect all cables.

performed Complaints
see page 18

1.6 Insulation test of stator windings (star point must be opened and T24, T25, T26
disconnected)

 a) Stator winding phase U against ground 

Resistance ............. MΩ Voltage ............. V

 b) Stator winding phase V against ground 

Resistance ............. MΩ Voltage ............. V

 c) Stator winding phase W against ground 

Resistance ............. MΩ Voltage ............. V

1.7 Insulation test of stator windings (star point must be opened)

 a) Stator winding phase U against phase V 

Resistance ............. MΩ Voltage ............. V

 b) Stator winding phase U against phase W 

Resistance ............. MΩ Voltage ............. V

 c) Stator winding phase W against phase V 

Resistance ............. MΩ Voltage ............. V

Insulation test instructions

LV generators
A 1000V megger or similar instrument should be used. Disconnect any earthing conductor connected
between neutral and earth and megger an output lead terminal U, V or W to earth. The 1 minute
insulation resistance reading for the total winding should be in excess of 10 MΩ to earth. Should the
insulation resistance be less than 10 MΩ the winding must be dried out as detailed in the Service and
Maintenance section of this work instruction.

Cummins Generator Technologies Germany GmbH Page 7

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MV & HV generators
A 2500V (MV) / 5000V (HV) motorised megger or similar instrument should be used. Separate the three
natural leads, ground V and W leads and megger U to ground. Repeat for V phase with U and W grounded
and W phase with U and V grounded. The 1 minute insulation resistance for each phase should not be less
than 100 MΩ (MV) / 300 MΩ (HV) and the polarisation index should be in the order of 2 or greater and
20 ºC. (PI = IR10min / IR1min)
If the IR is lower than described above, check for the reason of low IR values ( i.e. humidity, dirt, wrong
connection).

It should be noted that as winding temperature increases values of insulation resistance will significantly
reduce. Therefore true values of insulation resistance should be established with windings at ambient
temperatures.

performed Complaints
see page 18

 1.8 Resistance measurement of stator 

Caution!

Before static winding resi stances are measured, the generator set should be shut
down, isolated and proved dead.

 1.9 Check and re-tightening of all screws and nuts 

in main terminal box by dynamometric key

 1.10 Cleaning and examination of insulators for cracks 

Terminal box should be cleaned by vacuum cleaner

Insulators to be cleaned with dry cloth or electrical cleaner and cloth

 1.11 Re-tightening of contact screws and nuts on 

auxiliary terminal strip

 1.12 Resistance measurement of all auxiliary windings / PMG 

Measurement at UH 1-2 / WH 1-2 / UH 3-4 / WH 3-4

Cummins Generator Technologies Germany GmbH Page 8

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performed Complaints
see page 18

 1.13 Resistance measurement of exciter stator 

 1.14 Insulation test of auxiliary windings 

 1.15 Examination of anti-condensation heater 

............. V ............. A

The ambient conditions in which a generator is operated or stored should be fully understood, to ensure
the generator is maintained in a fully serviceable condition. Areas for consideration include
temperature, humidity and vibration levels. In stand-still the anti-condensation heaters should be activated.
Within the generator’s storage or installed area, thermostatic control of space heaters will be of
considerable assistance.
Observe CGT storage instructions in case of longer ( > 6 months) standstill time of the alternator.

 1.16 Insulation resistance measurement of rotor winding

 a) Insulation measurement main rotor 

Resistance ............. MΩ Voltage ............. V

 b) Insulation measurement exciter rotor 

Resistance ............. MΩ Voltage ............. V

 1.17 Resistance measurement of rotor 

A 500V megger or similar instrument should be used. Minimum acceptable values after 1 minute are:

New machine In-service machine

Exciter stator 10 MΩ 5 MΩ
Combined rotor 200 MΩ 100 MΩ

If the IR is lower than described above, check for the reason of low IR values ( i.e. humidity, dirt, wrong
connection).

Cummins Generator Technologies Germany GmbH Page 9

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performed Complaints
see page 18

 1.18 Inspection of rotating rectifiers 

The rotating rectifier assembly is mounted on the generator shaft end near the non drive end
bearing. Access can be achieved by removal of the rectifier cover.
The diodes on the main rectifier assembly can be checked with a multimeter. The flexible leads
connected to each diode should be disconnected at the terminal end, and the forward and reverse
resistance checked. A healthy diode will indicate a very high resistance (infinity) in the reverse
direction. A faulty diode will give a full deflection reading in both directions with the test meter on the
10,000 ohms scale, or an infinity reading in both directions.
On an electronic digital meter a healthy diode will give a low reading in one direction and a high reading
in the other.
Compare the readings of the rectifiers in operation with new ones during same temperature condition.
Varistor and diode reverse check with 500V insulation measuring instrument.
Check for discolorations and signs of high temperature.
Check for cable chafing and mechanical stress to the cables and cracks in rectifier blocks.

 1.19 Inspection of stator end winding (please take pictures) 

 1.20 Inspection of rotor winding (please take pictures) 

Cummins Generator Technologies Germany GmbH Page 10

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II. Mechanical Inspection

performed Complaints
see page 18

Sleeve Bearing Design

YES NO
Oil lubrication system installed:  

If YES:

Oil flow DS:  

Oil flow NDS:  

Hydrostatic function installed:  

Hydrostatic function checked:  

Pressure indication

After pump started: DS High Value: .................... NDS High Value: ....................

After shaft lifted: DS Low Value: ..................... NDS Low Value: ....................

Inspection of sleeve bearing

 Check type of oil (provided by customer) 

Oil viscosity used: .................... according to ISO VG ....................

 2.1 Check of oil level in sleeve bearing (30% to 50% of level gauge) 

Oil level O.K.  not O.K. 

 2.2 Check for leakage of sleeve bearings 

 2.3 Check of oil quantity in oil lubrication system 

 2.4 Check of oil pressure in oil lubrication system: 

.................... mbar

performed Complaints
Cummins Generator Technologies Germany GmbH Page 11
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see page 18

 2.5 Check of oil temperature in oil lubrication system 

 2.6 Check of air pressure inside the bearing housing 

.................... mbar (max. 5 mbar)

 2.7 Check of lubrication ring 

 2.8 Check for any corrosion on drive side and non-drive side bearing 

Roller/Ball Bearing Design

Roller bearing manufacturer / type (if applicable): ..............................................................

Type of grease: ..............................................................

 2.9 Roller/Ball bearing: Check of bearing noise (hand turning) 

 2.10 Manual check of bearings and vibration 

 2.11 Relubrication of roller/ball bearing according to operating instructions 

(depends on bearing type)

Scales available Yes  No 

Grease storage clean Yes  No 

Tools clean Yes  No 

 2.12 Visual check of grease colour in bearing 

Bearing grease colour has to be checked between rollers and running surface. Grease has to be soft and not
black.

 2.13 Removal of surplus grease 

 2.14 Removal of old grease from bearing covers 

performed Complaints
see page 18
Cummins Generator Technologies Germany GmbH Page 12
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Additional Mechanical Checks

 2.15 Inspection of abrasion at earthing brush and slip rings 

 2.16 Inspection of base frame for mechanical deviations 

Mounting of alternator / Check of feet fixation (take pictures)

 2.17 Visual inspection of the drive coupling 

 2.18 Check of inlet and outlet airducts for dust and dirt 

 2.19 Check of inlet and outlet airducts for corrosion, dirt or loose particles 

 2.20 Cooler / leakage monitoring 

 2.21 Check of drainage stoppers / drainage for condensation 

water

 2.22 Torque check for electrical assembly (steel property class: 8.8) 

Bolted assembly steel – brass Bolted assembly steel – copper

Dimension Torque [Nm] Dimension Torque [Nm]

M4 2,5 M4 1,5
M5 4,5 M5 2,5
M6 8 M6 4,5
M8 20 M8 10
M10 40 M10 20
M12 65 M12 40

performed Complaints
see page 18

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 2.23 Torque check for mechanical assembly 

Bolted assembly steel - steel

Dim. Porperty class Torque [Nm] Abm. Porperty class Torque [Nm]
8.8 3,0 8.8 295
M4 10.9 4,6 M18 10.9 421
12.9 5,1 12.9 492
8.8 5,9 8.8 415
M5 10.9 8,6 M20 10.9 592
12.9 10,0 12.9 692
8.8 10,1 8.8 567
M6 10.9 14,9 M22 10.9 807
12.9 17,4 12.9 945
8.8 16,8 8.8 714
M7 10.9 24,7 M24 10.9 1017
12.9 28,9 12.9 1190
8.8 24,6 8.8 1050
M8 10.9 36,1 M27 10.9 1496
12.9 42,2 12.9 1750
8.8 48 8.8 1428
M10 10.9 71 M30 10.9 2033
12.9 83 12.9 2380
8.8 84 8.8 1928
M12 10.9 123 M33 10.9 2747
12.9 144 12.9 3214
8.8 133 8.8 2482
M14 10.9 195 M36 10.9 3535
12.9 229 12.9 4136
8.8 206 8.8 3208
M16 10.9 302 M39 10.9 4569
12.9 354 12.9 5346

III. Test Run

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Please attach a copy of the protection relay setting and a single line diagram of the power station.

performed Complaints
see page 18

Precaution!

 3.1 Check whether earthing switch is disconnected before start up 

 3.2 Check of bearing noise (hand turning not possible at sleeve bearings) 

 3.3 SPM bearing analysis: DE: LR .......... HR .......... 

NDE: LR .......... HR .......... 

 3.4 Check of oil amount in sleeve bearings during operation 

 3.5 Effectivity of lubrication ring 

 3.6 Test tripping of temperature protection, alarm and shut down levels 

 3.7 Check signals and contacts between alternator and external control systems 

 3.8 Vibration test / Vibration values (mm/s) 

DE: .......... Hor. .......... Ver. .......... Axi.

NDE: .......... Hor. .......... Ver. .......... Axi.

Frame: ............. Airduct inlet: ............. Airduct outlet: .............

Output: ............. kW

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performed Complaints
see page 18

 3.9 Check of regulator functions at no-load operation 

a) Exciter current at rated voltage and rated speed:

I1-I1': ............. A

b) Exciter current at rated load:

I1-I1': ............. A

c) Supply voltage: UH1-UH2: ............. V

UH1-WH2: ............. V

WH1-WH2: ............. V

d) Under speed protection setpoint: ............. Hz

 3.10 Check of parallel operation 

Check of distribution of load

Voltage droop adjustment .......... %

 3.11 Check of overcurrent and short circuit protection trip 

 3.12 Check of differential protective trip 

 3.13 Check of exciter monitoring system 

XE2 
EDM200 
Other modules 

 3.14 Check of generator voltage in parallel operation 

grid voltage min.: ............. kV

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

Cummins Generator Technologies Germany GmbH Page 16

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performed Complaints
see page 18

 3.15 Bearing and winding temperature after continuous 

operation

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

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IV. Maintenance Result

Complaints:

___________________________________________________

___________________________________________________

___________________________________________________

___________________________________________________

___________________________________________________

___________________________________________________

___________________________________________________

___________________________________________________

 The operation of the alternator can be continued without immediate

elimination of the complaints.

 Electrical and mechanical checks were performed without any

complaints.

 The alternator must be stopped immediately due to the complaints.

________________ ________________________
(Date) (Signature Customer)

________________________
(AvK-Service-Technician)

Cummins Generator Technologies Germany GmbH Page 18

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Please revert to our work instructions

Cummins Generator Technologies Germany GmbH

Bunsenstraße 17
85053 Ingolstadt, Germany
Phone: +49(0)841-792-0
Fax: +49(0)841-792-250
e-mail: info@[Link]
[Link]

Cummins Generator Technologies Germany GmbH Page 19

[Link]
Regulator Description
Description and adjustment instructions
”COSIMAT N+” voltage regulator
for DSG and DIG alternators

Cummins Generator Technologies Germany GmbH

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Description of ”COSIMAT N +”
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2. Brief summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 General diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Adjusting elements and their effects . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Optimising the regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3. Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Monitoring alternator voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4 Desired value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Droop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.6 Control amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.7 Additional functions of the ”COSIMAT N+” . . . . . . . . . . . . . . . . . . . . . 10
3.7.1 Underspeed protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.7.2 Protection functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.8 Power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4. Transfer function of the ”COSIMAT N+” . . . . . . . . . . . . . . . . . . . . . . 12

5. Special functions and additional equipment . . . . . . . . . . . . . . . . . . . . 13

5.1 Stand-by and emergency manual switchover . . . . . . . . . . . . . . . . . . . . . 13
5.2 Additional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

7. Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

8. Diagrams of connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.1 Assembly for DSG alternators 52 – 74 . . . . . . . . . . . . . . . . . . . . . . . 21
8.2 Assembly for DSG alternators 86 – 125 . . . . . . . . . . . . . . . . . . . . . . . 22
8.3 Assembly for DIG medium-voltage alternators with UN ≤ 11.5 kV . . . . . . . . . . . . 23
8.4 Assembly for DIG medium-voltage alternators with UN > 11.5 kV . . . . . . . . . . . . 24
8.5 De-excitation circuit on the ”COSIMAT N+” . . . . . . . . . . . . . . . . . . . . . 25
8.6 Monitoring field current and voltage on the ”COSIMAT N+” . . . . . . . . . . . . . . 25

9. Connections, adjusting elements and displays . . . . . . . . . . . . . . . . . . . 26

9.1 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.2 Adjusting elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.3 Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

10. Start-up of the ”COSIMAT N+” . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

10.1 Basic setting and visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.2 Desired value setting range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.3 Regulating parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.4 Underspeed protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.5 Droop adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

11. Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

11.1 Protection concept for external mounting of regulator . . . . . . . . . . . . . . . . . 30
11.2 Mounting the regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.3 Excitation build-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.4 Code switch S2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.5 Droop switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.6 Changing the direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.7 Synchronous motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.8 Protection fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.9 Drying out the alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.10 External power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
11.11 400 Hz alternators and converters . . . . . . . . . . . . . . . . . . . . . . . . . 32
11.12 Checking the insulation voltage of the electric machine . . . . . . . . . . . . . . . . 32
11.13 Exchange/replacement; ”COSIMAT N/N3” by ”COSIMAT N+” . . . . . . . . . . . 32
11.14 Malfunctions, causes and remedies . . . . . . . . . . . . . . . . . . . . . . . . . 33

12. ListCummins
of figures
Generator
. . Technologies
. . . . . .Germany
. . . GmbH
. . . . . . . . . . . . . . . . . . . . . . . . . . 36
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1. General With the use of additional modules it is possible to intervene
in set-point and actual value formation via the ”COSIMAT N+”
The ”COSIMAT N+” is a compact voltage regulator designed signal inputs:
to control synchronous alternators both in single and parallel
operation. There are a large number of additional modules available for
a wide variety of control applications e.g.
In single operation, the alternator voltage is held constant
irrespective of power, frequency and temperature. ● cos phi regulation of a synchronous alternator or motor

When operated in parallel with the mains or with other or

alternators, a stable reactive power is produced.
● Limitation of start-up current when connecting up a large
Via its power stage, the ”COSIMAT N+” adjusts the excitation asynchronous motor to the alternator
current to match the operating conditions.
or
The main features of the ”COSIMAT N+” are:
● Cable compensation via load current detection or mea-
● Integrated measuring transformers for three-phase meas- sured value of the external alternator voltage.
urement of the alternator voltage up to 500 V AC
(external conductor voltage). Its additional modules make the "COSIMAT N+" suitable for
various applications on test rigs, in power-train technology
● Stable reactive power thanks to current-voltage vector etc. (see 5.2 Additional modules).
measuring system (droop). A load-relieved current trans-
former is required in alternator phase ”V”.

● Internal and external alternator voltage set-point ad-

justment.

● PID control amplifier with large adjustment range.

● Disproportionate drop in desired value when alternator

operates at underfrequency.

● Permanent monitoring of the actuator and time limit on

the max. possible excitation current.

● Internal protection devices trip whenever a fault occurs,

thus separating the excitation field from its energy source.

● Compact construction with interchangeable power

stage.

● Fully potted in to protect it from environmental effects.

● Long life thanks to high-quality components.

Cummins Generator Technologies Germany GmbH 2

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2. Brief summary
2.1 General-arrangement diagram

Figure 1 – General-arrangement diagram

3 Cummins Generator Technologies Germany GmbH

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2.2 Adjusting elements and their effects

Figure 2 – Adjusting elements

Cummins Generator Technologies Germany GmbH 4

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2.3 Start-up

Figure 3 - Start-up

5 Cummins Generator Technologies Germany GmbH

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2.4 Optimisation of the regulator It is not necessary to adjust the D parameter in order to
optimise the control properties. It is generally determined just
To optimise regulation, it is necessary to connect loads to the once, in accordance with the size of the alternator. In the case
alternator. of alternators > 1 MVA, switch S2.4 is switched to the ON
position.
To allow the trend of the control property following a change
in the P or I parameter to be evaluated, the load connected To decide whether the D parameter should be increased
must be reproducible. beyond this, it is necessary to take specific measurements of
the alternator voltage and at the output of the regulator.
The factor with the greatest general significance in achieving
an optimum regulating system is an overshoot amplitude xm Satisfactory optimisation of the regulator will normally be
which is as small as possible. The essential criterion in the achieved by the free adjustment of the P and I parameters.
evaluation of the regulating process with respect to time is the
settling time taus.

To follow the trend of the control property, use an oscilloscope

to monitor the manipulated variable.

The "COSIMAT N+" regulator allows ”free” adjustment of the

P and I parameters. The D parameter can be switched over
in two stages using code switch S2.4.

Figure 4 – Characteristic quantities of the regulating system

Figure 5 – Trend of the control property

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3. Functional description
3.1 Block diagram

Figure 6 – Block diagram

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3.2 Power supply 3.3 Monitoring alternator voltage

Power is supplied to the "COSIMAT N+" by means of The "COSIMAT N+" measures alternator voltages from 90 to
so-called auxiliary excitation voltages, which are produced 500 V AC (external conductor voltage) within two selectable
in the alternators. The excitation energy and the supply ranges by means of an internal three-phase measuring trans-
voltage for the "COSIMAT N+" are derived from the auxiliary former.
excitation voltages.
To measure higher voltages, corresponding voltage transfor-
In the case of AvK alternators in Series DSG and DIG with mers must be connected in series.
UN ≤ 11.5 kV, the "COSIMAT N+" is supplied with power
via two single-phase auxiliary windings, which are inserted Signal input N allows intervention into the internal formation
into the main stator. The windings are designated UH1/UH2 of the actual value.
and WH1/WH2.
The secondary AC measurement voltage of the measuring
The voltages UH1 and UH2 are offset by 90° with respect transformer is converted into a DC voltage, smoothed, condi-
to WH1 and WH2 and are 80 V AC ± 20 % at the nominal tioned and output as an actual value to the regulator circuit.
voltage of the alternator.
The measured value which is produced corresponds to the
In the case of AvK alternators belonging to Series DIG with arithmetic mean of the rectified three-phase AC measurement
UN > 11.5 kV, the "COSIMAT N+" is supplied with power voltage.
via a two-phase auxiliary exciter machine. The windings are
designated UH1, UH2, UH3 and WH1, WH2. Three-phase measurement allows for asymmetric loads.

The voltages UH1 and UH2 are offset by 90° with respect Note:
to WH1 and WH2 and are 80 V AC ± 20 % at the nominal For non-linear loads (static thyristor converter or rectifier),
speed of the machine. additional module TF (RC – low-pass filter) is recommended
as a measuring adapter. High non-linear loads may
The above-mentioned auxiliary exciter windings UH1 and require overdimensioning of the alternator.
UH2 and WH1 and WH2 are plugged into the correspon-
dingly designated terminals of the "COSIMAT N+":
3.4 Desired value
Special application
Three-phase auxiliary exciter machine The desired value for the "COSIMAT N+" is taken from a
If a three-phase auxiliary exciter machine is used, the winding temperature-compensated reference source.
terminals are designated UH1-VH1-WH1. The external con-
ductor voltage is 3 x 75 V AC ± 20 % at the nominal speed The signal input ”n” allows intervention in the internal formation
of the machine. of the desired value.

Special application The reference voltage reaches the set-point potentiometer R 4

External power supply mounted on the front end of the "COSIMAT N+". This
The "COSIMAT N+" can also be operated with a constant potentiometer allows coarse adjustment of the alternator
external voltage. It is generally supplied via a three-phase voltage over a wide range (= ”approximate” desired value).
transformer (Yy 0) with a secondary voltage of 3 x 75 V AC
± 20 %. The nominal power should be at least 500 VA. In parallel operation of the alternator, the reference voltage
is influenced by the droop-measuring system (see 3.5 Droop)
and, in the case of underfrequency, by the underspeed
protection.

A set-point potentiometer can be connected to the "COSIMAT N+"

Caution: for external adjustment of the desired value.

If the auxiliary excitation voltage is taken This potentiometer is used for fine adjustment of the alternator
from a constant "external" power source (e.g. voltage (= ”exact” desired value).
the mains), the supply must be switched on
only after the alternator has been started. The adjustment range is limited to ± 5 % to ± 10 % around
When switching off the alternator, the the nominal value, depending on the potentiometer used.
supply should be switched off before the
machine comes to a halt (see 11.10 External The ES additional module allows the adjustment range of the
power supply). external set-point potentiometer to be extended from remanence
to the nominal voltage.

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If the ES module is used on AvK alternators, the regulator If, when the alternator is connected in parallel, the fixed mains
system must be provided with an external power supply. This forces it down to a figure which is 6 % lower, the reactive
must be decided on a case by case basis, depending on the current is inductive and equivalent to 100 % of the nominal
application and the excitation system used (auxiliary excitati- alternator current.
on windings or auxiliary excitation machine?)
In parallel operation, regulation of the synchronous alternator
is made possible by the droop sensing signal.
3.5 Droop For stand-alone operation, adjustment is performed on the test
rig using a reactive load. The droop effect is set to 3 %.
Once an alternator has been connected in parallel, voltage
regulation is no longer possible because the system voltage The droop sensing signal in the "COSIMAT N+" influences
is fixed. The slightest fluctuation in the system voltage would the desired value and is produced by means of a geometrical
lead to the alternator producing reactive current > IN. addition of the external conductor voltage U-W and a
current-dependent voltage signal from the V phase.
To stabilise the alternator reactive current it is therefore
necessary to have a measured variable which is dependent In AvK synchronous machines, the corresponding current
on the reactive current and incorporates the magnitude of the transformer is located in phase V. The K side of the transfor-
current and the reactive power (inductive or capacitive). This mers points towards the alternator’s main winding (see Figure
measured variable is introduced at the addition point (com- 6 – Block diagram).
parison point of the desired value and the actual value) of the
control amplifier circuit. Internally load-relieved bushing-type transformers are used.

This produces a static droop control characteristic, which The outlet end of the secondary connections ( = potted end
represents the relationship between: of the transformer) is the primary-side K point (= current input).

the change in the alternator voltage in relation to the nominal The wire marked in white is the secondary-side k point.
voltage and
the change in the alternator reactive current in relation to the The secondary connections k and I of the droop current
nominal current. transformer should be plugged into the correspondingly mar-
ked terminals of the "COSIMAT N+".
The droop is represented by the slope of the characteristic
curve produced i.e. is the quotient of the above ratio. In the case of alternators for parallel and stand-alone opera-
tion, the measuring input k – I can be short-circuited by means
In the "COSIMAT N+" a linear droop characteristic is gene- of a switch for stand-alone operation. This gives better voltage
rated. The droop effect can be adjusted from 0 to 6 % using stability (see 8. Diagrams of connections, 11.5 Droop
the potentiometer R 7. switch).

Example: The droop sensing system of the "COSIMAT N+" is matched

In the case of an inductive reactive current of 100 % of the to the nominal current of the alternator by means of potentio-
nominal current of the alternator and with the droop set to 6 %, meter R 6.
the alternator voltage is reduced by 6 %.

Caution:

For the droop sensing system to function

correctly, the "COSIMAT N+" requires a
clockwise rotating field at its measurement
voltage terminals. If the direction of rotation
is reversed, measuring leads U and W
should be interchanged.

3.6 Control amplifier

The control amplifier of the "COSIMAT N+" has a PID

characteristic. The parameter of the I section can be varied
in steps from 1 to F using switch S 1. During this process, the
integration time constant increases.
Figure 7 – Droop characteristic

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 kink point” is set to 0.95 x fN. Above the kink point, voltage
Caution: regulation is constant.

Switch position 0 is not allowed; never pass The voltage reduction is delayed by about 2 seconds to
through 0. eliminate the effect of transient drops in the speed of the drive
machine.

The parameter of the P section can be varied by means of In exceptional circumstances, the underspeed protection fun-
potentiometer R 1. During this process, the adjustment range ction can be deactivated by means of code switch S2.2 (see
shown in Figure 8 should not be exceeded. 9.2 Adjusting elements).

Caution:

For standard applications of the "COSIMAT N+",

the underspeed protection function must be
active and correctly set. Code switch S2.2
must be in the ”ON” position.

The underspeed protection function is active on 50/60 Hz

alternators. For other nominal frequencies, the UF module
should be used or the alternator should be deexcited when
being shut down.

Figure 8 – P adjustment range

Further adjustment in the clockwise direction leads to hunting,

while further adjustment in the anticlockwise direction leads
to control errors.

The D parameter can be changed by switching code switch

S2.4 to the ”ON” position. This increases the effect of the D
parameter, as required by larger alternators (DIG and DSG
74 ... 125).

The D parameter can furthermore be varied at the ”D-Opt.”

optimisation points. At the specified polarity, a capacitor can
additionally be soldered in.

When installing additional D-section capacitors, it is important

to note their polarity (electrolyte capacitor) and nominal
voltage (= 35 V DC). The maximum recommended value is
150 µF.

Figure 9 – Underspeed protection

3.7 Additional functions of the "COSIMAT N+"
3.7.2 Protective functions
3.7.1 Underspeed protection
The auxiliary exciter windings (see 3.2 Power supply) have a
While a drive machine (motor or turbine) is warming up, the very high short-circuit capacity. If the actuator is faulty, the
alternator is operated at underfrequency. To prevent overexci- high short-circuit power involved may cause severe damage.
tation and thermal damage in the exciter system, the "COSI-
MAT N+" allows frequency-dependent reduction of the To prevent this damage, the "COSIMAT N+" has two protecti-
regulator’s desired value or alternator voltage in accordance ve functions which monitor its actuator and prevent overloa-
with a linear function (see Figure 9 – Underspeed protection). ding of the exciter system:

The point at which the voltage drops is defined by a corre-

sponding frequency value set by means of R3. The reduction
for underspeed is indicated by H1. Before delivery, the ”U/f

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Time limitation of the maximum excitation cur- 3.8 Power stage
rent
The power stage of the "COSIMAT N+" provides an excita-
When the actuator is fully on, the excitation current tion current that corresponds to the output signal of the control
reaches a maximum. amplifier.

If this state is allowed to continue, the exciter system will A MOSFET transistor is used as the actuator, with pulse width
be damaged. modulation, i.e. the turn-on time varies but the switching
frequency remains constant.
However, the fully-on state only occurs in the case of
compensating processes or short circuits at the main The excitation energy is taken from the rectified supply
terminals of the alternator. voltage, the rectifier circuit being located in the power stage.
It allows the rectification of two single-phase or three-phase
The monitoring system of the "COSIMAT N+" limits supply voltages (see 3.2 Power supply).
maximum excitation to 8 to 10 seconds.
There is a short-circuit thyristor in the DC circuit. The protective
After this, the protection circuit isolates the exciter field circuit of the "COSIMAT N+" switches this thyristor on if faults
from the source of excitation energy by tripping the occur in the control circuit. The resulting short-circuit current
protection fuses. trips the two protection fuses on the front plate of the "COSI-
MAT N+" and the exciter field is isolated from the source of
Checking the direction of action of the control excitation energy.
amplifier and the actuator
Fuse:
This feature monitors the positioning transistor for short 10 A super quick-acting
circuits. 32 mm x 6.3 mm ø
IEC G 144.400
Short-circuiting of the positioning transistor leads to maxi-
mum excitation. The control amplifier tries to counteract
this but has no effect on the faulty actuator. The actuator
and the control amplifier act in opposite directions and Caution:
the fuses trip immediately.
Replacement fuses must be of the above type.
The following circumstances also lead to maximum excitation The power stage may suffer permanent dama-
and can trip the fuses: ge if the wrong type of fuse is used.

● Faulty sensor leads

The power stage is located on a profiled heat sink. It is
● Deactivated or incorrectly adjusted underspeed protecti- plugged into the regulator and screwed into the substructure
on function of the "COSIMAT N+".

● Short circuit in the I1 / K1 exciter lead To ensure adequate cooling for the power semi-conductors in
the power stage, you must follow the instructions in Chapter
● Faulty exciter rectifier in the "COSIMAT N+" 11.2 Mounting the regulator.

● Extreme overloading of the alternator (short circuit) if this

has not been switched off after 8 to 10 seconds.

The protection device integrated into the "COSIMAT N+"

responds to a large number of defects and faults.

Note:
Additional module ER1 can be used to limit the excitation
current when the alternator is operated in parallel.

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4. Transfer function of the "COSIMAT N+"

Figure 10 – Equivalent control circuit diagram

There are three ways of influencing the control parameters in The time constant of the input low-pass filter is:
the "COSIMAT N+”:
TP1 = 3.62 ms
Potentiometer R1 (500 kΩ) for changing the P parameter. At
the right-hand stop, R1 is 0Ω. The time constant of the output low-pass filter is:

Switch S1 for changing the I parameter in 15 steps (from 0.22 TP2 = 0.268 x T2
to 3.85 µF) each of 0.22 µF (C1).

Code switch S2.4 for increasing the D parameter from 10.1 µF

(S2.4 = OFF) to 32.1 µF (S2.4 = ON) (C2).

The individual parameters in the equivalent circuit diagram

(see Figure 10 – Equivalent control circuit diagram) can be
calculated as follows:

T1 = R1 x C1
T2 = 6,8 kΩ x C2
T3 = 22 kΩ x C1

TI = T1 + T2

TD = T1 x T2
T1 + T2

K1 =2,56 T1 + T2
T3

K2 = 716,1 ms x K1
Tl

K3 = 1 = 0,066
15

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5. Special functions and additional
equipment
5.1 Stand-by and emergency manual switchover

Where higher availability is required, there are ”stand-by”

circuits.

Stand-by circuits contain two "COSIMAT N+" voltage regula-

tors.

The alternator is regulated by one of these regulators (main

regulator). If this regulator is defective, it is possible to switch
to the second (stand-by) regulator.

Stand-by circuits are available in either manual or automatic

form.

Manual stand-by circuit (SB1)

In the event of a malfunction, a changeover switch permits

the stand-by regulator to be selected.

The changeover switch switches over all the signals apart

from the sensing voltage and supply connections UH2
(VH1) and WH2.

Automatic stand-by circuit (SB2)

The stand-by circuit monitors the main regulator.

Common operating variables with respect to the response

of the regulator allow fault detection and switchover to
the stand-by regulator.

The stand-by regulator operates in simulated control

mode and is likewise monitored.

The switch between the two regulators can take place

during the operation of the alternator and can be perfor-
med manually, by means of a test function or, in the case
of a malfunction, automatically.

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5.2 Additional modules

The following list provides a summary of the various additional

modules for the "COSIMAT N+".

COS
cos phi regulator

FUNCTION: The power factor (cos phi) is held constant

irrespective of fluctuations in system voltage or load changes.

APPLICATION: Parallel operation with fluctuating mains.

Limitation of the excitation current by means of ER1 additional
module.

Figure 11 – Additional module COS

QPF
Reactive power regulator with single-phase
measurement

FUNCTION: The reactive power is held constant irrespective QPF

of fluctuations in system voltage or load changes.

APPLICATION: Parallel operation with constant reactive

power output.

Figure 12 – Additional module QPF A

QPF
cos phi trimmer

FUNCTION: The power factor of the regulated alternator is

the same as that of the total current or of the currents of the
other alternators (depending on current transformer connecti-
on).

APPLICATION: Parallel operation with alternators without

linear voltage droop.

Figure 13 – Additional module QPF B

QPF
Reactive power trimmer with single-phase
measurement

FUNCTION: The reactive power of the regulated alternator

is the same as that of the other alternator.

APPLICATION: Parallel operation with alternators without

linear voltage droop.

Figure 14 – Additional module QPF C

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SB2
Automatic stand-by switchover
(see 5.1 Stand-by and emergency manual switchover)

FUNCTION: Automatic switchover to the stand-by regulator

in the event of regulator faults.

APPLICATION: Requirement for higher availability and ope-

rating reliability (e.g. on ships).

Figure 15 – Additional module SB2

TF/TF1
RC – low-pass filter
(Type TF1-50 for 50/60 Hz)

FUNCTION: Reducing the ripple effect in the voltage sensing

signal of the "COSIMAT N+".

APPLICATION: Non-linear alternator loading by rectifier

bridges or static converters.

Figure 16 - Additional module TF1

ES
Extended adjustment range
(incl. 10 x potentiometer)

FUNCTION: External adjusting range from remanence to

nominal voltage.

APPLICATION: Various test applications in the construction

of transformers and electrical machines, run-up of large
electric motors (pump motor).

Figure 17 – Additional module ES

UF
U/f characteristic module

FUNCTION: Frequency-dependent regulation of the alterna-

tor voltage in accordance with a linear function. Different
gradients can be selected.

APPLICATION: Variable-frequency operation of shaft alterna-

tors on ships. Reduces the speed dip when there is a jump in
the active load.

Figure 18 – Additional module UF

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UF3
U/f characteristic module with extension

FUNCTION: Frequency-dependent control of the alternator

voltage in accordance with freely selectable function. Ope-
ration with controlled inner field voltage down to 0 Hz.

APPLICATION: Control of the alternator voltage as a function

of any measured variable (using standardised measured-value
signal) and freely selectable characteristics. Used for driving
asynchronous winding motors and for testing transformers.

Figure 19 – Additional module UF3

SR2
Current limitation

FUNCTION: Limitation of alternator current to predetermined

value.

APPLICATION: Run-up of large electric motors.

Note: No effect on the switch-on peak in the case of direct
switch-on of motors or transformers.

Figure 20 – Additional module SR2

EI
External actual value detection

FUNCTION: Regulation to externally measured voltage. If the

measuring lead breaks, it switches over to voltage measure-
ment at the alternator terminal.

APPLICATION: Providing the consumer with highly accurate

voltages over long input leads.

Figure 21 – Additional module EI

UDC2
Detection of DC voltage actual value

FUNCTION: Electrically isolated measurement of a DC volt-

age actual value.

APPLICATION: Voltage regulation of a synchronous alterna-

tor to the rectification value of an output-side bridge-type
rectifier.

Figure 22 – Additional module UDC2

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KP
Cable compensation

FUNCTION: Raising the alternator voltage as a function of

the current.

APPLICATION: Compensation of cable voltage losses by

way of the load current, specifically when there is no possi-
bility of access to the external measuring point.

Figure 23 – Additional module KP

ER1
Controlling exciter current limiter

FUNCTION: Secondary regulation of the exciter current to a

selected over- and under-excitation value.

APPLICATION: Protects the alternator in cos phi-regulated paral-

lel operation with a ”soft” mains when using "COSIMAT N+" and
COS module.

When used with QPF, controlling limitation of the exciter

current cannot be used. In that case, it would be necessary
to employ contact indication in the event of the exciter current Figure 24 – Additional module ER1
limits being over- or undershot.

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6. Technical data

GENERAL DATA Type : fully potted aluminium housing incl. power stage
Maintenance : maintenance-free
Rated switch-on time : continuous operation
Installation position : mount with longitudinal axis vertical at
convectional cooling or longitudinal axis
in air flow direction at fan cooling
Installation clearance : 3 cm all round
(see 11.2 Mounting the regulator)

MEASURING CIRCUITS Alternator voltage

Nominal voltage : 90 ... 250 V AC / 250 ... 500 V AC
Frequency : 50 ... 400 Hz
Power consumption : 4 VA / 6 VA

Droop current sensing

(Voltage input)
Voltage at IN : 3 ... 7 V AC
Power consumption : 0.15 ... 0.35 W

AUXILIARY CIRCUITS Supply voltage : 2 x single-phase 80 V AC ±20 %

or
1 x three-phase 75 V AC ±20 %
Power consumption : depending on excitation requirement
Nominal frequency : 50 ... 1200 Hz

OUTPUT CIRCUITS Actuator

Intermediate circuit voltage UZK : 85 to 130 V DC
(dependent on the supply voltage)
Continuous excitation current : 7 ADC (continuous)
Minimum field resistance RIK : 5Ω (cold)
Minimum required
field time constant τIK : 0.06 s
Short circuit exciter current : 20 ADC for 5 seconds
(at RIK = Ω5 and UZK = 100 VDC)
Protective fuse : 10 A-FF / 250 V – 6.3 x 32

ACCURACY Control accuracy : ±1 % at 0 to 60 °C

±5 % speed fluctuations and
apparent power 0 ... 100 %

TESTS Vibration test : German Lloyd category 2

EMV : CE-compliant in accordance with EN50081
and EN50082

AMBIENT CONDITIONS Storage temperature : - 40 ... + 70 °C

Operating temperature : -25 ... + 70 °C
(Special version "COSIMAT N+T"
- 55 ... + 70 °C)

HOUSING, DIMENSIONS,
WEIGHT AND INSTALLATION Height x width x depth : 121 x 115 x 162.5 mm
Fixing : 4 M6 bolts, washers and circlips
Weight : 2 kg

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7. Dimensions

Figure 25 – Dimensions

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8. Diagrams of connections
Legend for diagrams of connections

F1 Circuit breakers for G3

Operate only when stationary

G1 Main machine

G2 Exciter/excitation windings

G3 Auxiliary windings/Auxiliary exciter machine

R11/V3 Rotating varistor

T24 Voltage transformer for regulator

Must be disconnected if the star
point of G1 is open

T32 Voltage transformer for G3

with integrated circuit breaker F1
Operate F1 only when stationary!

V1 Rotating rectifier

X1 Main terminals

X2 – 6 Terminal strip

U1 "COSIMAT N+" voltage regulator

R3 Underspeed protection

R4 Internal desired value

R1 P component

S1 I component

R7 Droop adjustment

R6 Droop transformer matching

R1 Desired value potentiometer alternator

voltage (R = 500Ω)

T6 Droop transformer

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8.1 Assembly for DSG alternators 52 - 74

Figure 26 – Internal mounting, DSG alternators 52 – 74

Figure 27 – External mounting, DSG alternators 52 – 74

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8.2 Assembly for DSG alternators 86 – 125

Figure 28 – Internal mounting, DSG alternators 86 – 125

Figure 29 – External mounting, DSG alternators 86 – 125

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8.3 Assembly for DIG medium-voltage alternators with UN ≤ 11.5 kV

Figure 30 - Internal mounting, DIG medium-voltage alternators with U N ≤ 11.5 kV

Figure 31 - External mounting, DIG medium-voltage alternators with UN ≤ 11.5 kV

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8.4 Assembly for DIG medium-voltage alternators with UN >11.5 kV

Figure 32 - Internal mounting, DIG medium-voltage alternators with U N > 11.5 kV

Figure 33 - External mounting, DIG medium-voltage alternators with UN > 11.5 kV

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8.5 De-excitation circuit on the "COSIMAT N+" 8.6 Monitoring field current and voltage on the
"COSIMAT N+"
If a de-excitation circuit is fitted, the bridges on the double
terminals UH1/UH1’ and WH1/WH1’ should be removed. The "COSIMAT N+" is provided with double terminals I1/I1’
Switch contacts should be connected to the double terminals and K1/K1’ to allow the exciter field to be connected. Bridge
to de-excite the alternator when they open (see Figure 34 – I1/I1’ must be removed to allow the field current and voltage
De-excitation circuit). These de-excitation contacts must meet to be monitored (see Figure 35 – Field current/field voltage
the following specification: monitoring).

Current carrying capacity:10 AAC The measuring range for field voltage monitoring is 150 VDC;
Voltage carrying capacity:160 V AC for field current monitoring it is 10 ADC. Rotary coil or
moving-iron instruments are recommended. Under certain
The switch elements used must have dust-protected contact conditions, digital instruments may give false readings.
chambers. Ensure that contact resistance is low – the contacts
must be sensitive to low-level signals. Note:
In the case of AvK alternators (DSG 86 – 125, DIG),
Note:
there are connecting terminals for monitoring the field
One of the factors which determines the build-up of
current and voltage on terminal strip X2.
excitation is the quality of these contacts.
On AvK alternators (DSG 86 – 125, DIG), connecting
terminals for de-excitation are provided in the auxiliary
terminal box (see legend of the order-specific circuit
diagram).

Figure 34 - De-excitation circuit

Figure 35 - Field current/field voltage monitoring

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9. Connections, adjusting elements and Monitoring droop current:
displays
k–I
9.1 Connections
4.8 x 0.8 mm flat plugs and/or 2.5 mm2/4 mm Ø screw
terminals
Voltage supply:

UH1 Caution:
UH2 (VH1)
WH1 Measuring input k – I is not a current input;
WH2 standard transformers should be load-relieved
accordingly.
4.8 x 0.8 mm flat plugs and/or 2.5 mm2/4mm Ø screw
terminals

Supply can be 2 x single-phase (80 V AC ± 20 %) or The droop current transformer must be installed in the "V"
phase of the alternator.
three-phase (75 V AC ± 20 % external conductor voltage).
Internally load-relieved droop current transformers are
2 x single-phase = UH1-UH2, WH1-WH2
used in AvK alternators.
three-phase = UH1-VH1-WH1
At the nominal current of the alternator, a voltage of 3 to
For de-excitation circuits, the bridges on the double
7 V AC is required at the terminals k – I (see 3.5 Droop
terminals must be removed (see 8.5 De-excitation circuit
and 6. Technical Data).
or order-specific circuit diagram).
Connecting leads to the transformer must be shielded if
Caution:
the regulator is installed externally. Connecting leads to
the short-circuit droop switch (see 11.5 Droop switch)
If there is an external power supply (e.g.
should be shielded in all cases. The shield should be
from the mains), it must not be switched on
earthed at one end on the "COSIMAT N+" (see 8.
until after the alternator has run up. It
Diagrams of connections).
should be switched off before the machine
has come to a halt (see 11.10 External
power supply).
Exciter field:

I1 – K1
Measuring alternator voltage:
4.8 x 0.8 mm flat plugs and/or 2.5 mm2/4 mm Ø screw
U-V-W 250 to 500 V AC terminals as double terminal.
U-V-W 90 to 250 V AC
If the regulator is mounted externally, the I1/K1 field leads to
6.3 x 0.8 mm flat plugs the alternator must be run through a separately shielded cable
(LSYCY or LIYCY).
Caution:
The shield should be earthed at one end on the "COSIMAT N+"
(see 8. Diagrams of connections).
A clockwise rotary field is required. If the
alternator rotates anticlockwise, U and W
should be interchanged (see 3.5 Droop).
External set-point potentiometer

The specified voltage ranges relate to the nominal exter- s–t

nal conductor voltage of the alternator. For higher volta-
ges, appropriate measuring transducers with a design 4.8 x 0.8 mm flat plugs and/or 2.5 mm2/4 mm Ø
rating of 10 VA should be connected on the input side screw terminals as double terminal.
(see 3.3 Monitoring alternator voltage).
The value of the set-point potentiometer determines the
The applicable voltage range should be taken from the adjustment range:
order-specific circuit diagram. For DIG alternators with
UN >1 kV, the range 90 – 250 V AC is generally chosen. 250 Ω = about ± 5 %
Consult AvK before initial start-up if required. 500 Ω = about ± 10 %

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 The rated power of the potentiometer must be at least 1 This potential is not connected when the "COSIMAT N+"
W. A multiple-turn potentiometer must be used (see 3.4 is used for standalone operation.
Desired value).

If the regulator or the set-point potentiometer is mounted 9.2 Adjusting elements

externally, the set-point lead must be provided with its
own separate shield. The shield should be earthed at one Underspeed protection
end on the "COSIMAT N+". If the regulator is mounted
externally and the set-point leads are longer than >10 m, R3
a motor-actuated potentiometer should be used near to
the "COSIMAT N+". 25-gang trim potentiometer

Function:
Control inputs: Adjustment of the frequency-dependent lowering of alter-
nator voltage (see 3.7.1 Underspeed protection).
N
M/m Direction of action:
n Left-hand stop = beginning of reduction at >50/60 Hz.
Right-hand stop = beginning of reduction only after
4.8 x 0.8 mm flat plugs and/or 2.5 mm2/4 mm Ø about > 30 Hz.
screw terminals.
In special cases, the underspeed protection can be
A number of additional modules from the "COSIMAT N+" deactivated by means of switch S2.2 (see 9.2 Adjusting
equipment range can be connected to these control elements).
inputs (see 5.2 Additional modules).
This is necessary when regulating a DC voltage by way
of additional module UDC or in some cases when using
Caution: external UF modules.

Only AvK additional modules must be used

at the control inputs. 20 mA standard si- Desired value:
gnals must not be used at these inputs.
R4

The inputs have the following functions: 25-gang trim potentiometer

N Access to the internal actual value circuit Function:

M/m Reference point for additional equipment Adjusting the alternator voltage (see 4.3 Desired value,
n Access to the internal desired value circuit 10.2 Desired value adjustment range).

Direction of action:
Circuit earth: Left-hand stop = minimum alternator voltage
Right-hand stop = maximum alternator voltage
-

The circuit earth is likewise used as reference potential Caution:

for a number of ”controlling” additional modules.
Before the "COSIMAT N+" is started up, R4
This potential is not connected when the "COSIMAT N+" must be turned to the left-hand stop position
is used for stand-alone operation. (see 10. Starting up the "COSIMAT N+"). A
regulator which is checked and delivered
together with an alternator is already preset.
Load earth:

Z
P component:
The load earth is used for connecting the internal interme-
diate circuit capacitors.
R1
Additional external capacitors can be connected between
the second Z connection tab (MINUS) and terminal I1 1-gang trim potentiometer
(PLUS).

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 Function: Direction of action:
Varying the proportional component of the control cha- Left-hand stop = maximum compensation value
racteristic. Right-hand stop = minimum compensation value

Direction of action: At nominal alternator current, R6 should be used to carry

Anticlockwise = small P component out trimming to 2.5 V AC at the measuring points
Clockwise = large P component ”MP-STATIK – DROOP”. If the alternator load current is
less than the nominal current, this may be trimmed to a
The recommended adjustment range shown in Fig. 8 – proportional voltage value.
P adjustment range must not be exceeded (see 10.3
Regulating parameters).
Code switch:
I component:
S2
S1
4-pole dip switch

Function:
Caution:

Switch position ”0” is not permitted. Switch FUNCTION ON OFF

S2.1 none ./. ./.

16-stage code switch Activation and
S2.2 deactivation Active Not
Function: of underspeed active
protection
Varying the I component in the regulating characteristic
(see 10.3 Regulating parameters). Reduction of
S2.3 actual value Nominal Reduced
smoothing
Direction of action:
Left (1 <- F) = small I component Increasing the
Right (1 -> F) = large I component S2.4 D-parameter Increased Nominal

Droop:
Required basic setting:
R7
AvK DSG alternators up to size 62:
1-gang trim potentiometer
S2.1 = no function
S2.2 = ON (underspeed protection)
Function:
S2.3 = ON (actual value smoothing)
Adjustment of the droop effect.
S2.4 = OFF (D parameter)
Direction of action:
AvK DIG, DSG 74 – 125 alternators
Left-hand stop = no droop effect (0 %)
parallel operation not possible.
S2.1 = no function
Right-hand stop = droop effect 6 %
S2.2 = ON (underspeed protection)
S2.3 = ON (actual value smoothing)
If the direction of rotation is reversed, sensing voltage
S2.4 = ON (D parameter)
connections U and W must be interchanged.

9.3 Displays
Droop matching:
Underspeed protection:
R6
H1
25-gang trim potentiometer
yellow 5 mm Ø LED
Function:
Matching the various alternator nominal currents and
current transformer ratios to the droop monitoring system.

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H 1 lights up when the desired value or lowering of alternator g) Is the field connected with the correct polarity?
voltage in the case of underfrequency is active (3.7.1 Under-
speed protection)
10.2 Desired value setting range
Caution:
Once all the basic settings and visual checks have been
carried out, the alternator can be started up.
The regulator is set during the testing of the
alternator at the factory. See test protocol a) Run up alternator to nominal speed.
and order-specific circuit diagram.
b) Set external set-point potentiometer to the central position.

c) Adjust nominal voltage using R4.

10. Starting up the "COSIMAT N+"
d) The alternator voltage can be adjusted around its
10.1 Basic setting and visual check nominal value using the external set-point potentiometer.

Before start-up, the following basic settings of the "COSIMAT N+"

voltage regulator must be checked: 10.3 Regulating parameters

R3 right-hand stop position a) If the basic settings of R1 and S1 (see 10.1 Basic setting
R4 left-hand stop position and visual check) lead to continuous periodic fluctuations
R1 central position (stability limit), adjust R1 slowly to the left.
(in the case of DIG, DSG alternators, 1/4
rotation anticlockwise from the central position) b) If there is temporarily a tendency towards weakly
damped hunting in the event of load surges, adjust S1 one
S1 Pos. 4 or two positions to the right.
(in the case of DIG, DSG alternators Pos. 6,
at 600/750 rpm Pos. 9)
S2 S2.1 = no function 10.4 Underspeed protection
S2.2 = ON
S2.3 = ON a) 50/60 Hz alternators to 0.95 x fN.
S2.4 = OFF (ON in the case of DIG and DSG
alternators from size 74) b) In the case of 50/60 Hz alternators, turn R3 slowly in
the anticlockwise direction starting from the right-hand stop
R7 Central position position until H1 lights up. Then turn it slowly in the clock-
R6 Left-hand stop wise direction until H1 goes out.

After basic setting, the following visual checks must be carried c) Run the alternator up to nominal speed.
out:

a) Have the sensing voltage connections (U, V, W 10.5 Droop adjustment

90...250 / 250...500) been correctly selected?
a) Load the alternator with nominal current. Measure the AC
b) Do the sensing voltage connections possess a clockwise- voltage at the droop sensing points ”MP-STATIK-DROOP”.
rotating field? (If rotation is anticlockwise, interchange U Adjust to 2.5 V AC using potentiometer R6.
and W).
b) For partial loading, the calibration value can be reduced
c) Is the supply voltage correctly connected (2 x single- proportionately.
phase UH1/UH2 and WH1/WH2; three-phase UH1,
VH1, WH1)? c) If a stronger droop effect is required, R7 (percentage
droop) should be turned clockwise starting from its central
d) Is the excess current circuit breaker in the alternator position.
switched on?
Note:
e) Is the droop transformer installed in the V phase? Where a number of alternators are run in parallel, the
droop device must be at the same setting in all the
f) Is the k – I phase position of the droop current transformer "COSIMAT N+" regulators and be active!
correctly connected? (In the case of external installation,
check from the alternator to the regulator).

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Recommended droop settings: to flow freely through its power stage. Note the installation
position marking ”UNTEN” (= BOTTOM) (connecting
3% Parallel to the mains (If the mains supply is not leads towards the power stage). At fan cooling, the longitu-
stable, the setting may have to be increased). dinal axis of the "COSIMAT N+" has to be in air flow
direction. Deviating mounting is only suitable after checking
2% Parallel operation with identical alternators. by AvK.

6% Parallel operation with different alternators whose There must be a 3 cm clearance all the way round between
regulators do not have a linear droop. the "COSIMAT N+" and any structural elements that might
hinder flow (cable ducts, plates). This rule does not apply to
1% Parallel operation with different alternators which laterally mounted additional modules.
also have "COSIMAT N” or ”N+" regulators.

11.3 Excitation build-up

11. Important notes
At the nominal speed, the auxiliary excitation windings on
11.1 Protection concept for external mounting DSG and DIG alternators must produce a remanent voltage
of regulator of at least 10 V AC in order to ensure a satisfactory excitation
build-up.
The following protective measures must be taken if the regu-
lator is installed externally in the switching station: However, problems with excitation build-up may also be
caused by dirty de-excitation contacts or a field connection
The sensing line U-V-W is to be laid using short-circuit-proof of incorrect polarity.
cable (1.5 mm2) from the alternator terminal strip X2 to the
switching station. AvK recommends the installation of a In the case of alternators which have been stationary for a
three-phase circuit breaker with a thermal tripping current of prolonged period, it may be necessary to introduce an
approximately 0.5 A. If this circuit breaker is tripped, the external excitation voltage. To do this, a 4.5 V or 6 V battery
alternator must be de-excited and stopped immediately. is briefly connected by its positive terminal to I1 and by its
negative terminal to K1 at nominal speed. In the case of
If the regulator is installed externally, the connecting leads for two-phase auxiliary excitation machines, the battery should
the external set-point potentiometer, the droop current transfor- be connected to I2(POSITIVE)/K2(NEGATIVE).
mer, the droop switch and the I1/K1 exciter line are to be
provided with separate shielding. The shields must be earthed
at one end on the "COSIMAT N+". 11.4 Code switch S2

Protection concept: For standard applications of the "COSIMAT N+", the following
The exciter system should be protected from excessive exciter basic settings must be made before start-up at code switch S2
currents and voltages by a field discharge switch or relay. (see 9.2 Adjusting elements):
This switch or relay should be connected as shown in the
relevant order-specific circuit diagram. The tripping criteria AvK DSG alternators up to size 62
will be determined by the protection required by the alterna- S2.1 = no function
tor. S2.2 = ON (underspeed protection)
S2.3 = ON (actual value smoothing)
Where the alternator is operated in stand-alone mode, an S2.4 = OFF (D parameter)
overvoltage protection system must be installed in the swit-
ching station. In the case of operation in parallel with the AvK DIG and DSG 74 – 125 alternators:
mains or other alternators, an overcurrent protection system is S2.1 = no function
to be added. S2.2 = ON (underspeed protection)
S2.3 = ON (actual value smoothing)
DSG/DIG alternators with auxiliary windings: S2.4 = ON (D parameter)
DSG and DIG alternators with auxiliary windings are fitted
with an excess-current circuit breaker F1. This protects the Any differences from these settings must be agreed with the
auxiliary windings from excessively high thermal loading e.g. manufacturer beforehand and taken into account in the way
as the result of an external short circuit involving the auxiliary the alternator is operated.
exciter voltage UH1-UH2 or WH1-WH2.

11.5 Droop switch

11.2 Mounting the regulator
If alternators are to be used for both single and parallel
The "COSIMAT N+" must be mounted with its longitudinal operation, better voltage stability can be achieved in single
axis vertical in case of convectional cooling to allow the air

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operation if the k – I inputs of the "COSIMAT N+" are it is installed in the synchronous machine and the way the
short-circuited (see 8. Diagrams of connections). droop current transformer is connected to the "COSIMAT N+"
remains the same (see 8. Diagrams of connections).
The lead between the droop switch and the regulator must be
screened. For motor control, a cos phi controller (COS module) is
required additionally.
The screen must be earthed at one end on the "COSIMAT N+".

Caution:

In parallel operation, the switch must be

opened.

11.6 Changing the direction of rotation

To enable the droop sensing system to exercise the correct

effect, the "COSIMAT N+" requires a clockwise-rotating field
at its measuring voltage connections.

Caution:

If the direction of rotation is reversed, in-

terchange sensing leads U and W.
Figure 36 – Modes of operation of a synchronous machine
Note:
The desired direction of rotation should be specified
when ordering the alternator. This is important with 11.8 Protective fuses
regard to ventilation.
When the protective fuses are tripped, they must be replaced
with fuses of the same type.
11.7 Synchronous motors
Fuse type:
Synchronous motors operate in a similar way to synchronous
alternators in parallel operation. The direction of the active
10 A super quick-acting IEC G 144.400
power is rotated through 180° relative to the alternator (see
Figure 36 – Operation of the synchronous machine).
Caution:
Starting from cos phi = 1, this has the following implications
for the reactive power: The power stage may be permanently da-
maged if slow or medium time-lag fuses
● Given a rising exciter current (overexcitation), the synchro- with a rating equal to or higher than 10 A
nous machine becomes a source of reactive power. are used!

● Given a falling exciter current (underexcitation), the synchro- Two spare fuses are mounted on the underside of the "COSI-
nous machine becomes an acceptor of reactive power. MAT N+" (see 7. Dimensions).
When used as a generator, the synchronous machine is taken
as the reference point; where it is used as a motor, the mains 11.9 Drying out the alternator
are taken as the reference point.
If, because of inadequate insulation resistance, the alternator
When used as a generator, the synchronous machine supplies has to be dried out at nominal current by the short-circuit
”inductive” reactive power to the mains when overexcited. method, the "COSIMAT N+" should be disconnected from
the supply and exciter field connections.
When used as a motor, the synchronous machine draws
”inductive” reactive power from the mains when underexcited. The alternator is dried out by applying an external source of
excitation.
The droop system in the "COSIMAT N+" operates with the
correct direction of action whether the machine is being Further information on how to dry out the alternator can be
operated as a motor or a generator. The direction in which found in the alternator instructions.

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11.10 External power supply must be connected to the correspondingly named connecting
terminal of the "COSIMAT N+".
If the auxiliary exciter voltage is taken from a different,
”external” source (e.g. the mains), the supply must not be
switched on until the alternator has started up.
When shutting down the alternator, the supply must be
switched off before the machine comes to a halt.

The switch-on and switch-off point of the supply should be set

to 0.95 x fN using a frequency relay (BF1).

The double terminals at connections UH1 and WH1 can be

used to switch the supply on and off (see 8.5 De-excitation
circuit).

Caution:

When the alternator is stationary and an

auxiliary exciter voltage is applied, the
exciter current flowing is at its maximum!
The protective circuit of the "COSIMAT N+"
will trip the protection fuses on the front
plate after about 8 seconds.

11.11 400 Hz alternator/converter

On 400 Hz alternators < 100 kVA (as single machines or

converters), switch S2.3 must be set to the "OFF" position.

11.12 Checking the insulation voltage of the

electric machine

Before checking the insulation voltage of the electric machine,

the following connections of the "COSIMAT N+" must be
disconnected:

Measuring voltage U, V, W
Supply UH1-UH2, WH1-WH2
Exciter field I1-K1

The supply and measurement connections of additional regu-

lator components must also be disconnected.

All disconnected or interrupted connections should be isolated

in the appropriate manner.

11.13 Exchange/replacement; "COSIMAT N/N3"

by "COSIMAT N+"

On AvK alternators of series DSG, DIDBN, DIDBH and DIG,

sizes ...74-86-99-114-125, switch S2.4 on the "COSIMAT
N+" should be switched to the ”ON” position. Switches S2.2
and S2.3 should be switched to the ”ON” position. Switch
S2.1 should be set to the ”OFF” position.

The sequence of terminals WH1 and WH1’ has been

reversed on the "COSIMAT N+". The connecting cable WH1

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11.14 Malfunctions, causes and remedies

Malfunction Cause Remedy

Alternator voltage is too low. Input speed too low. Check whether LED H1 on regulator
lights up. If so, underspeed protection
device has been activated, run up al-
ternator to nominal speed.

Measuring leads incorrectly con- Check measuring-lead connections U,

nected. V, W on the regulator. Check whether
the nominal voltage of the alternator is
within the voltage range indicated on
the "COSIMAT N+".

Alternator voltage is too low and can- Set-point potentiometer or its con- Check set-point potentiometer or its
not be adjusted with the set-point po- necting leads are disconnected/inter- connecting leads. Rectify fault.
tentiometer. rupted.

Alternator voltage is too high. Broken measuring lead. Rectify fault.

Measuring leads incorrectly con- Check measuring lead connections U,

nected. V, W on the regulator. Check whether
the nominal voltage of the alternator is
within the voltage range indicated on
the "COSIMAT N+".

Alternator voltage is too high and can- Set-point potentiometer or its con- Check set-point potentiometer for short
not be adjusted with the set-point po- necting leads have a short circuit. circuit. Change potentiometer. Check
tentiometer. set-point leads for short circuits. Elimina-
te short circuit.

Severe voltage dip upon loading. Input speed falls upon loading. Check regulator of driving machine.

Defective protection fuse. Check protection fuse on the regulator

and exchange if necessary.

Rotating diodes defective. Check rotating diodes V1 and surge

voltage protector V3 and R11 and
exchange if necessary.

Alternator does not respond to excitati- Input speed too low. Less than 0,5 x nN. Check the speed regulator of the input
on. machine. Check the power transmissi-
on to the alternator.

Exciter protection switch has tripped. Switch on the protective switch again.
If it trips once more, search for the fault
and repair it.

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Malfunction Cause Remedy

Alternator does not respond to excitati- Remanence too low. Alternator with auxiliary winding:
on. Briefly connect positive terminal of 4.5
or 6 V battery to I1 and negative
terminal to K1 (at nominal speed).
Alternator with two-phase auxiliary
exciter machine:
Briefly connect positive terminal of 4.5
or 6 V battery to I2 and negative
terminal to K2 (at nominal speed).

DSG, DIG alternators: With alternator standing still!

Interruption in the auxiliary exciter win- Check windings UH1/UH2 and
dings. WH1/WH2 for interruptions using an
ohmmeter. Eliminate faults.

DIG alternators (UN ≤ 11,5kV): With alternator standing still!

Interruption in the auxiliary exciter Check windings WH1/WH2 and
machine windings. UH2/UH1/UH3 for interruptions
using an ohmmeter. Eliminate faults.

DSG, DIG alternators: With alternator standing still!

Interruption in exciter windings I1/K1. Check windings I1/K1 for interruptions
using an ohmmeter. Eliminate faults.

DIG alternators (UN > 11.5 kV): With alternator standing still!
Interruption in exciter windings I1/K1 Check windings I1/K1 and I2/K2 for
and/or I2/K2. interruptions using an ohmmeter. Elimi-
nate faults.

Fault in regulator. Check protective fuses and exchange

if necessary. Is the regulator receiving
excitation release and are the bridges
present at the double terminals I1/I1’,
K1/K1’, UH1/UH1’ and WH1/WH1’?
Check and eliminate fault.

Fault in the regulator connections. Check all regulator connections, input

and output leads. Eliminate faults.

Regulator defective. Exchange regulator.

Rotating diodes defective. Check rotating diodes V1 and voltage

surge protector V3 and R11 and
exchange if necessary.

Periodic fluctuations in the alternator Incorrect regulator setting. Adjust R1 carefully in the anticlockwise
voltage when operated singly (stability direction and turn S1 one or two steps
limit)! to the right.

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Malfunction Cause Remedy

Alternator voltage fluctuates at irregular Temporary interruption in one of the Check connecting leads to the regula-
intervals. regulator supply leads. tor. Check connections at the terminal
board of the alternator. Tighten all con-
tact screws and nuts.

Mechanical regulator of the driving Check speed regulator of the driving

machine is sticking. machine. Eliminate fault.

Reactive power output too high in par- Droop set too low. Adjust R7 slightly in the clockwise di-
allel operation. rection on the "COSIMAT N+".

Transformer connections k/I have Open bridge.

been bridged by the droop switch.

Phase angle connection (k/I) of the Check connecting leads from the alter-
droop current transformer has been nator to the regulator. Interchange k/I
wrongly positioned. if necessary. The white secondary con-
nection of the droop current transformer
is ”k”.

Droop switch is not in alternator phase Install droop transformer in phase ”V”.
”V”.

Measuring voltage connections U, V, Check the sensing lead. "COSIMAT

W wrongly positioned. N+" requires a clockwise-rotating field.
Interchange U and W if necessary (in
the case of anticlockwise rotation).

Reactive power output too low in par- Droop set too high. Adjust R7 slightly in the anticlockwise
allel operation. direction on the "COSIMAT N+".

Measuring voltage connections U, V, Check the sensing lead. "COSIMAT

W wrongly positioned N+" requires a clockwise-rotating field.
Interchange U and W if necessary (in
the case of anticlockwise rotation).

Active load not equally distributed. This is affected by the driving machine Check the drive motor and its regulator.
only.
The "COSIMAT N+" affects only the
reactive power.

We reserve the right to make technical changes.

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12. List of figures

Figure 1 General arrangement diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Figure 2 Adjusting elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 4 Characteristic quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 5 Trend of the control property . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 6 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 7 Droop characteristic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 8 P adjustment range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 9 Underspeed protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 10 Equivalent control circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 11 Additional module COS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 12 Additional module QPF A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 13 Additional module QPF B . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 14 Additional module QPF C . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 15 Additional module SB2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 16 Additional module TF1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 17 Additional module ES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 18 Additional module UF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 19 Additional module UF3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 20 Additional module SR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 21 Additional module EI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 22 Additional module UDC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 23 Additional module KP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 24 Additional module ER1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 25 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 26 Internal mounting, DSG alternators 52 – 74 . . . . . . . . . . . . . . . . . . . . 21
Figure 27 External mounting, DSG alternators 52 – 74 . . . . . . . . . . . . . . . . . . . . 21
Figure 28 Internal mounting, DSG alternators 86 – 125 . . . . . . . . . . . . . . . . . . . 22
Figure 29 External mounting, DSG alternators 86 – 125 . . . . . . . . . . . . . . . . . . . 22
Figure 30 Internal mounting, DIG medium-voltage alternators with UN ≤ 11.5 kV . . . . . . . . 23
Figure 31 External mounting, DIG medium-voltage alternators with UN ≤ 11.5 kV . . . . . . . . 23
Figure 32 Internal mounting, DIG medium-voltage alternators with UN > 11.5 kV . . . . . . . . 24
Figure 33 External mounting, DIG medium-voltage alternators with UN > 11.5 kV . . . . . . . . 24
Figure 34 De-excitation circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 35 Field current/field voltage monitoring . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 36 Modes of operation of a synchronous machine . . . . . . . . . . . . . . . . . . . 31

Cummins Generator Technologies Germany GmbH 36

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 Cummins Generator Technologies Germany GmbH
Bunsenstraße 17
85053 Ingolstadt, Germany
Phone: +49(0)841-792-0
Fax: +49(0)841-792-250
e-mail: info@[Link]
[Link]

Cummins Generator Technologies Germany GmbH

Dreieich Office
Benzstraße 47-49
63303 Dreieich, Germany
Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40
e-mail: info@cumminsgeneratortechnologies

Cummins Generator Technologies Germany GmbH

POD-regmodule-AvK-eng-cosimatN+.doc

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Cooler Description
Description for double tube closed-circuit cooler
Operating and maintenance manual

Cummins Generator Technologies Germany GmbH

[Link]
1/8
Contents

1. General ...................................................................................................................................3
2. Installing and removing the cooler ...............................................................................................3
3. Commissioning.........................................................................................................................4
4. Cooling water velocity................................................................................................................4
5. Measures to assure for the build-up of a protective film ..................................................................5
6. Standstill of the cooler................................................................................................................5
7. Service control and performance test............................................................................................6
8. Cleaning..................................................................................................................................6
8.1 General ............................................................................................................................6
8.2 Mechanical cleaning ...........................................................................................................6
8.3 Hydraulic cleaning ............................................................................................................7
8.4 Chemical cleaning .............................................................................................................7
9. Identifying and rectifying of leaks.................................................................................................7
9.1 General ............................................................................................................................7
9.2 Pressure test of individual tubes.............................................................................................7
9.3 Plugging of tubes................................................................................................................7
9.4 In serting a second inner tube...............................................................................................7
9.5 Pressure test after repair of cooler .........................................................................................8
9.6 Drying of leakage space......................................................................................................8

Cooler description – double tube page 2

Air/water cooler I-0602/Rev. 0
Cummins Generator Technologies Germany GmbH
[Link]
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 side. Please refer to relevant contractual drawings
1. General and piping / flow diagrams.

Depending on construction, the cooler can be

The AvK double tube closed circuit cooler is a
either inserted into a casing or mounted
finned tube heat exchanger. The air to be cooled
separately.
flows over the fins on the outside of the tubes and
emits the heat to the cooling water flowing
If condensation on the air side occurs, drainage
through the tubes. The heat exchange surface of
must be carried out through the drain nozzle fitted
the cooler consists of round inner tubes with
to the sidewall.
continuous flat plate fins over the bundle width.
The outer tube are grooved on the inside using an
If requested, the scope of supply can be extended
even inner tube or the inner tube is knurled using
to include casing frames, air ducts, doors, valves,
an even outer tube.
leak-detectors, level relays etc. for each cooler.
After inserting and expanding a space for leakage
Maintenance instructions for most of these parts
water remains between the inner and outer tube.
are not necessary, others like valves etc. are not
included in this booklet. Please see separate
The outer tubes are rolled into the air-side tube
instructions if your delivery includes any of these
sheets and the inner tubes are rolled into the
parts.
water-side tube sheets. The air- and water-side
tube sheets are bolted together with gaskets
If necessary, leakage air filters (preferably dry
interposed forming an intermediate air space.
medium type) for compensation of air losses in air
circuit can be added on cold air side or cold air
For the purpose of stiffening the cooler
duct.
construction and guiding the air flow the cooler is
constructed with sidewalls, which are bolted to the
tubesheets.

Water headers (namely nozzle- and return- 2. Installing and removing the
header) are provided for water handling. The cooler
number of separating baffles in the headers
depends on the number of water passes required. Prior to installing the cooler, the transport covers
The headers are bolted to the tube sheets, gaskets at the air faces and the blanks on the water
interposed to form a seal. Plugs or cocks in the connection flanges are to be removed. The air
headers serve the purpose of cooler venting and and water side sealing faces must be cleaned with
draining. turpentine if anti-corrosion protected.

The material for headers, water-side tube sheets The cooler is inserted into the air ducts using
and core tubes are chosen in accordance with the gaskets or sealing compound.
specification of the cooling water to be used and
the specific operating conditions. The cooling water pipes are connected to the
nozzle header flanges using appropriate gaskets.
The materials are chosen based on the
project information and should always be Remark:
checked by user. Also changes in these The gaskets for connecting the cooler to
conditions should be guarded by user. external piping are normally not supplied
with the cooler.
Generally, the cooler is mounted in a way, that
the air passes the machinery and the cooler in a To avoid deformation and stresses acting upon
closed circuit. The air is circulated by an internal the cooler when installed, the connecting surfaces
or external fan. The cooler can consist of one or must be parallel and the tolerances kept as small
several bundles mounted vertically, horizontally or as possible.
resting on one sidewall. In order to achieve the
performance required, the bundles can be Remark:
connected in series or parallel on air and water Due to unavoidable thermal expansion or
relative movement of the electrical machine

Cooler description – double tube page 3

Air/water cooler I-0602/Rev. 0
Cummins Generator Technologies Germany GmbH
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to environment the use of flexible joints / satisfactory the cooler can be taken into
piping is highly recommended. operation.

The sidewalls are provided with transport lugs for After setting the cooling water flow according to
lifting and handling the cooler. specification and operating the generator with
nominal load, the air in- and outlet temperature
Prior to dismantling, the cooler must be drained. should be measured to control, that the cooling
This can be done by draining the complete system is operating correctly.
cooling water system or draining the cooler only.
When draining the complete system the ventplugs Warning:
must be removed to assure the cooler will be The maximum allowed operating pressure
completely drained. When draining the cooler must not be exceeded and water velocities
only, the water in- and outlet valves must be must be kept within recommended range
closed before the drain- and vent-plugs are (see 4.)
removed.
4. Cooling water velocity
After loosening the flange bolts and removing
piping or aggregates, that may obstruct the work,
The following water velocities must be maintained
the cooler can be removed.
during operation:
For re-installation of the cooler the use of new
gaskets is necessary.
Tube material Min. velocity * Max. velocity
A suitable lifting gear should be used to extract CuZn28Sn 1.0 m/s 2.0 m/s
the cooler bundle in the direction that is indicated CuZn20Al 1.0 m/s 2.2 m/s
on the general arrangement drawings. CuNi30Fe 1.5 m/s 3.0 m/s
CuNi10Fe 1.0 m/s 2.5 m/s
3. Commissioning Cu 0.8 m/s 1.8 m/s
Other Acc. to special
request
The cooler is subject to a hydraulic pressure test * The minimum velocity should not be applied for
in the works of our sub-supplier. However, to a long period of time
assure that the cooler has not been damaged
during transport, it is recommended to carry out a The cooler should be operated with nominal
test with the specified test pressure before water flow, if possible.
commissioning the cooler.
Frequent fluctuations of the water velocity impede
If, after prolonged storage or extended standstill, the build-up of a protective film on the cooler
the header gaskets are leaking, tightening of the materials, which is vital for corrosion protection. A
header bolts should prevent further leakage. If this too low water velocity encourages dirt deposits
does not prove sufficient, the header gasket must and a too high velocity causes erosion. Throttling
be replaced. A pressure test with specified test of the water flow or improper positioning of the
pressure must be carried out after replacement. water intake can lead to air accumulations in the
cooler which favours corrosion. If air
After installation of the cooler is completed and accumulation occur, ventilation according to
the cooling water circuit is filled, the cooler must chapter 3 is necessary. During part-load
be vented by removing the vent plugs in the operation the water velocity should not subside
headers.. After the air has escaped, the plugs can below the minimum allowed water velocity.
be fitted again. Venting should be repeated Appropriate control devices should be installed
shortly after the cooler has been taken into for regulating water flow.
operation. Venting of the complete cooling system
in connection with venting of the cooler is more A bypass system as shown below has proved
efficient and therefore preferable. suitable for this requirement. Bypassing is done by
mixing the discharged warm cooling water with
If the cooler comprises of several bundles, each the cold water at the suction side of the pump to
bundle must be vented separately. assure operation at almost uniform air outlet
temperature. Consequently, the feed temperature
After a leak test has been carried out on all cooler of the cooling water can be controlled and the
components and the water circuit is operating water flow maintained constant in the cooler.

Cooler description – double tube page 4

Air/water cooler I-0602/Rev. 0
Cummins Generator Technologies Germany GmbH
[Link]
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 attack by putrefaction products such as
ammonium compounds and hydrogen sulphide.

If possible, cooler operation should not be

interrupted during the first 2 months after
commissioning if the cooler can not be drained.

However, if there is a failure in cooling water

supply and operation is resumed within 3 days
time and then for a prolonged period of time
uninterrupted, the cooler may be left undrained.

Layout of a bypass control system It must be then guaranteed that the tubes are free
of deposits. If deposits have formed, the cooler
should be drained, the tubes cleaned and rinsed
In case of continuously constant load and cooling with clean water prior to being dried. We
water flow the above mentioned bypass cooling recommend the use of warm or pre-dried air for
water regulation is not necessary. blowing through the tubes. If sea water, brakish or
saline water (chloride content > 500 mg/l) is
used for cooling rinsing with fresh water with low
5. Measures to assure for the build-
content of salt is necessary.
up of a protective film
In case of standstill within the start-up period of 2
The inherent good chemical corrosion resistance months, which is expected to last more than 3
of copper and copper alloys is due to their ability days and where deposits must be feared, the
to form an oxide protective film. cooler should be drained, rinsed and dried.

New cooler tubes lacking a strong protective film To avoid standstill corrosion after the first two
should never be operated with polluted water, as months of operation the above described
deposits on the material surface would prevent cleaning procedure should be repeated by every
the build-up of a protective film. standstill lasting longer than two weeks.

For the above reason, clean fresh water is always In case of permanent service interruptions after
used for the hydraulic test of the coolers. The the start-up period it may be necessary to limit the
utilisation of polluted or aggressive water with standstills where the cooler is kept undrained up
lack of oxygen should also be avoided during test to 3 days and operate the unit under conditions
runs. as recommended for the start-up period.

It is recommended to add small amounts of easy During short service interruptions the cooler can
dispensable iron sulphate (FeSO4-H2O) into the be operated at low cooling water velocity if build-
cooling water during test runs. This will support up of deposits in the tubes can be prevented.
the development of a protective film. Injection Operating with low water velocities is to be
should be done by a regulating valve near the preferred to cooling water standstill in the tubes
water intake with an amount of 5 grams of iron as putrefaction products, such as ammonium
sulphate per each m3 water flow for 1 hour in compounds and hydrogen sulphide are washed
every 24 hours. away from the tube walls.

6. Standstill of the cooler During a winter time standstill where a frost injury
to the cooler could occur, the cooler should be
A standstill incorporating the cooling water drained even during the shortest standstill. The
system, leaving the cooler undrained, is other suitable mean is the use of freezing
hazardous for cooler parts made of copper, protective additives (glycol).
copper alloys, steel and cast-iron.
Remark:
For copper and copper alloys standstills are Content of glycol must be known from the
especially hazardous prior to the build-up of a design stage of the power plant as glycol
protective film, or, in the case that the destruction will influence the heat transfer properties
of the same must be feared for reason of deposit significantly. In case of any change in

Cooler description – double tube page 5

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Cummins Generator Technologies Germany GmbH
[Link]
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cooling water composition, please contact The cooler parts in contact with water
the manufacturer. should be checked for corrosion damage
regularly. The recommended initial time
period is one year. Longer time periods
7. Service control and performance might be acceptable, based on site
experience.
test

For service control, temperature probes may be

installed on the air and water in- and outlet sides
8. Cleaning
of the cooler. Please refer to relevant equipment
data sheets and monitoring diagrams (circuit 8.1 General
diagrams). We recommend to keep record of the
air and water temperatures in the machine log Cleaning of the air and water side heat exchange
book periodically. Further control devices can be surfaces is imperative for a long and trouble-free
provided as individually required. operation of the cooler.
In case of major condensate occurance, further As the re-circulated air in electrical machines is
condensation can be prevented or at least limited clean, it is normally only necessary to clean the
by a control of the cooling water temperature waterside of the cooler.
(bypass control).
Regular cleaning is necessary. The cleaning
A possibility to drain the condensate is given at intervals vary with the quality of the cooling water
the lowest point of the cooler air duct. and the mode of operation. Please see remark in
chapter 7.
The performance guarantee given by AvK is
expressed by the temperature difference between The cleaning of the tubes is not only necessary to
water inlet and air outlet during nominal maintain the thermal cooler performance.
operation. Deposits, forming in the tubes, favour a higher
corrosion caused by air accumulation under these
This temperature difference should be checked deposits (pitting corrosion) and an erosion
from time to time. because of higher water velocity caused by a
lower cross-section.
Given, that the correct water flow is adjusted and For this reason the water cooler parts that are in
other machine parameters are within contractual contact with water should be inspected regularly
ranges and a considerable increase of the latest after a one year period.
guaranteed temperature difference is observed,
this might be due to air accumulations on the The cooler can be cleaned by mechanical,
water side of the cooler. To remedy the above the hydraulic or chemical means.
cooler should be vented using the procedure
described under 3.. 8.2 Mechanical cleaning

In case that a performance increase can not be Mechanical cleaning is done by the use of nylon
achieved by proceeding as above and provided brushes fitted to a rod. Brushes can be delivered
that no other disturbance can be found, the on demand. Mechanical cleaning can be done
cooler needs cleaning. in-situ or with the cooler removed. At least, one
water header must be removed to get access to
The water side differential pressure can be the tubes by loosening the fixing bolts and by
considered as an indication for cooler cleaning disconnecting the water connection.
being needed. We recommend to install
differential pressure gauges in the water in- and Warning:
outlet pipe system. After commissioning of the In case of cleaning in-situ, make sure that
cooler, the differential pressure is measured and the spray water does not penetrate the
recorded. From time to time, the measured value electrical machine.
is to be compared with the first record value.
Cooler cleaning is necessary as soon as the The wet tubes should be thoroughly brushed
differential pressure increases. clean one after the other and the dirt rinsed out
until no residues are left. After the cleaning is
Remark:

Cooler description – double tube page 6

Air/water cooler I-0602/Rev. 0
Cummins Generator Technologies Germany GmbH
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completed the headers are re-fitted using new cooler is not re-commissioned immediately
gaskets. after cleaning. Normal cooling water can
be used for rinsing.
For commissioning after cleaning, please proceed
as under chapter 3. For commissioning after cleaning, please proceed
as under chapter 3.
8.3 Hydraulic cleaning

Hydraulic cleaning is carried out when the cooler 9. Identifying and rectifying of
is removed using a high pressure spray gun with
leaks
special nozzles to remove dirt deposits. Please see
sketch below:
9.1 General

Tube leaks can be caused by corrosion, erosion

or improper operation of the cooler.

If leakage occurs on the inner tubes, the leak

water will be collected in the grooves formed
between inner and outer tubes and let into the
intermediate room between air- and water-side
8.4 Chemical cleaning tube plates. Leakage water will be detected at the
leakage drain holes in the header frame or, if an
Chemical cleaning is carried out with or without optical electrical leak detector is installed, alarm
the cooler removed and is required if neither can be actuated on a control panel.
mechanical nor hydraulic cleaning proved
successful. After leakage is noticed, the defective tube must
be identified. If this cannot be done by a visual
The complete cooler with headers is connected on inspection, a pressure test of the cooler or an
the waterside to an external cleaning circuit over individual pressure test of each tube has to be
flanges or it is filled with detergent. The cleaning carried out.
time is depending on the degree of pollution.
Cleaning must be repeated if the result is still not 9.2 Pressure test of individual tubes
satisfying after one cleaning cycle.
Prior to pressure testing, the nozzle and return
We recommend the use of the following cleaning header must be removed. Rubber plugs can be
detergents: used for pressure testing. One of the plugs must
have a connection for air or water supply. The
P3-T288 Henkel KGaA, Düsseldorf tube to be tested is plugged at both ends and
SAF-ACID DREW AMEROID GmbH, tested at low pressure applied via the plug having
Hamburg the connection for air or water.
VECOM BA-S VECOM GmbH, Hamburg
A pressure gauge should be installed to indicate a
The instructions and handling guidelines loss of pressure. Even if there is only a small leak
provided by the detergent manufacturer in the tube a pressure loss is indicated shortly
should always be observed when using a after pressure application.
chemical detergent.
9.3 Plugging of tubes
Scaling deposits in the cooling tubes can be
removed by chemical cleaning as well. For Once the defective tube is found, it can be sealed
removal, a 10% HC1-acid is used with about with soft copper plugs on both sides. Using hard
0,5% inhibitor, especially suitable for the existing metal plugs could damage the tube sheet bores.
tube material, added. In that case a second inner tube as described
under 9.4 can not be inserted and correctly
Warning: expanded.
After cleaning as above, the cooler must be
rinsed thoroughly, i. e. no detergent In case that several tubes are leaking it must be
residues are allowed to be left in the decided whether the cooler performance will be
cooler. This is most important in case the

Cooler description – double tube page 7

Air/water cooler I-0602/Rev. 0
Cummins Generator Technologies Germany GmbH
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satisfactory for emergency operation after
plugging.
In this case we generally recommend a complete
replacement and an investigation for failure
reason.

9.4 Inserting a second inner tube

To remedy tube leaks, plain tubes of smaller

diameter than the defective tube can be inserted
and expanded. Expanding the second inner tube
guarantees that a thermal contact is formed and
the thermal performance remains good.

If a tube expansion is not possible, it must be

decided at site wether or not the performance is
sufficient.

9.5 Pressure test after repair of cooler

After repair of cooler as described above, the

repaired cooler must undergo a pressure test at
specified test pressure.

9.6 Drying of leakage space

In order to prevent that residual water remaining

in the leakage space after a leakage will not
cause any later damages, the leak space has to
be dried with compressed air or pre-heated air.
The air is blown through the leak openings in the
header and water-side tube sheets.

Cooler description – double tube page 8

Air/water cooler I-0602/Rev. 0
Cummins Generator Technologies Germany GmbH
[Link]
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Allgemeines Datenblatt General Data Sheet
KSR-Bypass-Niveauschalter ABAU-GL By - Pass Level Switch ABAU-GL

Technische Daten Technical Data

Anschlussgehäuse Alu-Druckguß, 65x60x38 mm Terminal Box Pressure Die–Cast
Aluminium, 65 x 60 x 38 mm
Gehäuse und Aluminium ALMg 5 Chamber and Flange Aluminium ALMg 5
Flanschmaterial Material
Gleitrohr Edelstahl 1.4571 Guide Tube 316 TI Stainless Steel
Edelstahlschwimmer Typ SVK - Ø 44 mm Float Type SVK Ø 44 mm
Nenndruck 6 bar Rated Pressure 6 bars
Minimale Dichte 800 kg/m³ Minimum Specific Gravity 800 kg/m³
Kontaktfunktion U=Umschalter Contact U=Change – Over
48 W/ 220 VAC/DC / 1 A 48 W/ 200 VAC/DC / 1A
Maximale Temperatur 150°C Maximum Temperature 150°C
Schutzart IP65 Enclosure Rating IP65

MS- cable entry, brass,

Kabeleinführung in accordance with
nach DIN 89280 DIN 89280
housing:
Aluminium- terminal box
Anschlußgehäuse aluminium

Eintauchtiefe bei immersion depth

Dichte 1 sp. gravity 1
Ermeto-Verschraub screwed pipe
ungen connection
Gehäuse aus (Ermeto)
Aluminium AIMg 5 Aluminium AIMg 5

Ablassschraube
G¼ drain plug G ½”

Zulassungen: Germanischer Lloyd Approvals: Germanischer Lloyd

American Bureau of Shipping American Bureau of Shipping

Cummins Generator Technologies Germany GmbH

Ingolstadt Branch
Bunsenstraße 17
85053 Ingolstadt
Germany
[Link] Phone: +49(0)841-792-0
info@[Link] Fax: +49(0)841-792-250
Replacement Parts
 AvK REPLACEMENT PARTS
Description Standard Options Part Number Pieces
AVR
Cosimat N+ NI500048901 1

Rotating Diodes
DD 89 /14 NI910058582 3

Varistor Varistor TVA 40751 KBKCL501 NI910035009‐MP 2

Roller Bearing DE
6336 MC3 T7.300.319.0 1
Roller Bearing NDE
6328 MC3 T7.300.041.0 1
Technical Data
 Technical Data Sheet for AvK-Alternators FM 7.3-5

Date: 03/05/2012 Customer: Wärtsilä Finland Oy

Project No.: P-12.10579 FIN AvK Reference: 1-434-0000458-1
Object data:
Site: Auxpac 2 Prime Mover: Diesel engine
Application: Marine Manufacturer: Wärtsilä 8L20
Generator data:
Generator: DSG 99 M1/8 W Poles: 8 Standards: IEC 60034; DNV
Rated power: 1775 kVA 1420 kWe 1480 kWm
Power factor: 0.80
Power at pf 1,0 1435 kVA 1435 kWe 1480 kWm
Rated voltage: 0.69 kV
Speed: 900 1/min
Frequency: 60 Hz Voltage range / frequency range:
Rated current: 1485.2 A Zone A according IEC 60034-1 (dU = +/-5%, df = +/-
2%)
Winding pitch: ca. 5/6
Insulation class: Stator: Class H Rotor: Class H Temperature rise: F
Ambient temperature: 45 ° C Environment: Standard environment
Site altitude: 0m
Enclosure: IP44 Filter:
Cooling: IC 81W - watercooled
Coolant: Freshwater Temperature 38 ° C Temperature Air inlet 53 ° C
Coolant: generator:
Cooling air vol.: 3.0 m³/s Cooling water quantity: 7.6 m³/h
Moment of inertia (I): 205 kgm² Weight: 7000 Kg Losses (environment): 7 KW
Losses (cooling): 53 kW
Connections and regulators:
Wires: 4 terminals, starpoint connected in terminal box
Operation mode: Island mode with different generators in parallel
Regulators:
Voltage regulator: DECS 100
Electrical data: (acc. IEC)
Efficiencies: 110% 100% 75% 50% 25%
Power factor 0.8 95,76 95,96 95,94 95,21 93,27
Power factor 0.9 96,29 96,47 96,37 95,57 93,47
Power factor 1.0 96,82 96,97 96,8 95,93 93,67

Reactances and time constants

unsaturated saturated unsaturated saturated

xd 1.44 1.30 p.u. xq 0.72 0.71 p.u. Td0' 2.15 s Td0'' 0.02921 s
xd' 0.222 0.222 p.u. xq' 0.72 0.71 p.u. Td' 0.33 s Tq0' 0.3 s
xd'' 0.125 0.114 p.u. xq'' 0.126 0.126 p.u. Td'' 0.015 s Tq0'' 0.17143 s
x2 0.132 0.120 p.u. x0 0.037 0.034 p.u. Ta 0.045 s Tq' 0.3 s
x1s n.a. 0.068 p.u. Tq'' 0.03 s
Short circuit ratio saturated: 0.77 Zn 0.268 Ohm

Short circuit data:

Initial short circuit current (3-phase): Ik'' 13028 A
Max. peak current (3-phase): IS 33164 A
Sustained short circuit current: Ik 4456 A 3 x rated current for max.10 s
Initial short circuit torque: Mk2 214.8 kNm
Mk3 128.9 kNm
Max. faulty synchron moment: Mf 461.8 kNm
Rated kVA torque: MSN 18.83 kNm
Rated torque MN 15.06 kNm
Shaft torque MSh 15.69 kNm
Load application:
max. load application: 1199 kVA(corresponds to 67,57 % von 1775 kVA) Power: 1775 kVA
for Power factor 0.4 Power factor: 0.8
15% transient voltage drop transient voltage drop: -18.2 %
Remarks:
 Order specification for AvK-Alternators
FM 7.2-4
-technical-

~ Projekt checklist

Issued by: Sales department

Created by: Peter Heuvelman (jq205)

Released by: QuotationTool
Date: 03/05/12

CGT Order No.:

1 Spare parts order no.:
Others:
Customer: Wärtsilä Finland Oy
Revision no.: 1
Revision date: 03/05/12
Auxpac 2
2 Application / Project: Alternator type: DSG 99 M1/8 W

3 CGT quotation no.: 1-434-0000458-1 Quantity: 1

P-12.10579 FIN
4 Factory Project no.:
5 Customer Order no.: Mode of operation: Marine
6 Delivery Date:

7.1 Order Type:

7.2 Reference:
7.3 Valid drawing at order entry:
8 Marine / Ship operation:
9 Shipyard.:
10 New building no.:
11 Type of vessel:
12 Construction acc. to classification society: IEC 60034; DNV
13 Inspection acc. to classification society:
14 Mode of operation:
15 Supply type:
16

17 Rated data Rules, Standards

18 Output: 1775 kVA Standards: IEC 60034; DNV
19 P.F. Cos Phi: 0.80 R.I.S. Degree: VDE 0875 N
20 Voltage: 0.69 kV Insulation class: Class H
21 Current: 1485.2 A Temperature rise: F
22 Frequency: 60 Hz Ambient temperature: 45 ° C
23 Speed: 900 1/min Altitude at site: 0m

24 Technical data
27 Efficiency: see technical data sheet attached
28 Rated load at cos phi = 0.8: 95.96
29 Rated load at cos phi = 1: 96.97
30 Efficiency tolerance: acc. to VDE 0530, EN 60034
31 Reactances, time constants: see technical data sheet attached
32 Overspeed: 1,2 x rated speed for 2 min
33 Operating voltage range: Zone A according IEC 60034-1 (dU = +/-5%, df = +/-2%)
+/- 10% at no load for synchronisation, short term operation only
34 Operating frequency range: view line 33
35 Parallel operation: Island mode with different generators in parallel
36 Overload capability: 10 % for 1 h every 12 hours or 50 % for 30 sec.
37 3-phas. sustained short circuit current: 3 x rated current for max. 10 sec.

53 Design details, general

54 Design form: IMB 20 / IM 110x IM 1101

55 AvK project drawing:
59 Type of prime mover / Manufacturer and name of prime Diesel engine / Wärtsilä 8L20
mover:
62 Shaft end / -flange (DE): cylindrical shaft end
63 Rotation facing DE: counterclockwise
64 Surface treatment: Basic painting
Document: Revision: J dated 17.09.2004
7_2f04jE.xls Cummins Generator Technologies Germany GmbH 2/8
 Order specification for AvK-Alternators
FM 7.2-4
-technical-

65 Dynamic balancing: with half key at shaft end

70 Enclosure, Cooler

71 Enclosure alternator: IP44

72 Enclosure terminal box: IP20
73 Cooling type: IC 81W - watercooled

76 Cooler location: top

77 Coolant: Freshwater
78 Air inlet temperature inner circle: 53 ° C
83 Water inlet temperature: 38 ° C
84 Cooling water connections: Acc. to DIN 2633
86 Water pressure: Nominal pressure 6 bar, inspection pressure 9 bar
87 Cooler designed for: 1 x 100 % rated load
88 Cooler materials: Tubes CuNi10Fe / Cu
Plates CuZn38SnAl / steel zinc
Headers steel coated
Fins Al
89 Cooler equipment:
90 Leakage control / -filter ABAU-GL
91 Emergency flaps Emergency flaps IP20
92 Temperature detection 1 PT100 Air Outlet; 1 PT100 Air Inlet

98 Bearing arrangement + Lubrication

99 Bearing Design: Anti-Friction bearing

100 Calculated Lifetime: about 20.000 operating hours
101 Protection against shaft currents: Not insulated,

116 Terminal box + Accessories, Current transformers

117 Location main terminal box (seen on DE): Enlarged terminal box on top, integrated into cooler housing
119 Cable entry: Cable entry right
121 Cable gland plate: Drilled gland plate aluminium
122 Details, quantity + diameter of cables: Each phase: Cable qty. unknown; Type unknown; ODM unknown
N point: Cable qty. unknown; Type unknown; ODM unknown
123 Star point arrangement: 4 terminals, starpoint connected in terminal box
124 Location aux. terminal box (seen on DE):
126 Supplier of CT's: Transformers supplied by CGT
Transformers installed by CGT
127 Current transformers, starpoint side Core 1 Core 2 Core 3
128 - Primary current: 1500 A 1500 A
129 - Secondary current: 5A 5A
130 - Class: 10P10 10P10
131 - Burden: 15 VA 15 VA
132 - Standard test reports: Not applicable
134 Supplier of VTs: Transformers supplied by CGT
135 Voltage transformer(s) output side: Voltage transformer 3 phase LVDECS
136 - Transformation: 400/450/660/110 V - 40 VA
137 - Class 0.5
138 - Standard test reports for VTs: Not applicable

141 Voltage regulation system

142 Voltage regulator: DECS 100

Regulator function(s): Underexcitation limiter
Black Start Capability

148 Power supply of voltage regulator:: Aux. winding

149 Regulator location:

154 Instrumentation
155 Temperature detection stator windings: 6 PT100
156 Bearing temperature detection NDE-side: Single PT100
157 Bearing temperature detection DE-side: Single PT100
158 Temperature detection cooling air: 1 PT100 Air Outlet; 1 PT100 Air Inlet,
159 PT 100 design / connection: Standard design in 2-wire connection
162 Anti-condensation heater built-in: Supply voltage 230 V, 1-phase, 50/60 Hz, AC/DC
Power required 500 W

168 Works Tests

Document: Revision: J dated 17.09.2004
7_2f04jE.xls Cummins Generator Technologies Germany GmbH 3/8
 Order specification for AvK-Alternators
FM 7.2-4
-technical-

169 CGT Test: first generator: Type Test acc. to AvK Specification ING-PS-0005;
all other generators (if applicable):

170 Additional tests: not applicable

171 Works test witnessed by client: not applicable

174 Documentation / Dates:

175 Dimensional drawing: ca. 4 weeks after placement of order

177 Shaft drawing with moment of inertia: ca. 4 weeks after placement of order
178 Connection/terminal plan: ca. 6 weeks after placement of order
179 Drawings as DXF-File No
180 Operating instructions, Spare part lists: 2 weeks after works test
171 Test reports and Certificates: 2 weeks after works test
183 Number copies and language of documentation: 3 x German / 3 x English

190 Spare Parts, Tools

202 Additional details

203 Voltage matching: For Decs 100 and 200 the ratio of the sensing VTs
for generator and busbar voltage can be different.
Alternator is designed for inclinations of: 5°/7,5° Fore-and-Aft & 15°/22,5° Athwartships (stat./dyn.).
The altenatorshaft will be installed in parallel to the ships centerline.
Please contact the factory if alternator should be installed in athwarts direction.
Leistungsreduzierung des Generators auf 80% bei Ausfall Notfallbetrieb des Kühlers
Cross Current Compensation (CCC):
It must be ensured that CCC is de-activated when the mode
of regulation is changed from "AVR-mode" into "PF/VAR-mode".
Voltage matching: For Decs 100 and 200 the ratio of the sensing VTs
for generator and busbar voltage can be different.
Alternator is designed for inclinations of: 5°/7,5° Fore-and-Aft & 15°/22,5° Athwartships (stat./dyn.).
The altenatorshaft will be installed in parallel to the ships centerline.
Please contact the factory if alternator should be installed in athwarts direction.
Leistungsreduzierung des Generators auf 80% bei Ausfall Notfallbetrieb des Kühlers
Cross Current Compensation (CCC):
It must be ensured that CCC is de-activated when the mode
of regulation is changed from "AVR-mode" into "PF/VAR-mode".

Document: Revision: J dated 17.09.2004

7_2f04jE.xls Cummins Generator Technologies Germany GmbH 4/8
 Technical Data Sheet for AvK-Alternators FM 7.3-5

Date: 03/05/2012 Customer: Wärtsilä Finland Oy

Project No.: P-12.10579 FIN AvK Reference: 1-434-0000458-1
Object data:
Site: Auxpac 2 Prime Mover: Diesel engine
Application: Marine Manufacturer: Wärtsilä 8L20
Generator data:
Generator: DSG 99 K1/8 W Poles: 8 Standards: IEC 60034; DNV
Rated power: 1582 kVA 1424 kWe 1480 kWm
Power factor: 0.90
Power at pf 1,0 1434 kVA 1434 kWe 1480 kWm
Rated voltage: 0.69 kV
Speed: 900 1/min
Frequency: 60 Hz Voltage range / frequency range:
Rated current: 1323.7 A Zone A according IEC 60034-1 (dU = +/-5%, df = +/-
2%)
Winding pitch: ca. 5/6
Insulation class: Stator: Class H Rotor: Class H Temperature rise: F
Ambient temperature: 45 ° C Environment: Standard environment
Site altitude: 0m
Enclosure: IP44 Filter:
Cooling: IC 81W - watercooled
Coolant: Freshwater Temperature 38 ° C Temperature Air inlet 53 ° C
Coolant: generator:
Cooling air vol.: 3.0 m³/s Cooling water quantity: 7.1 m³/h
Moment of inertia (I): 173 kgm² Weight: 7250 Kg Losses (environment): 7 KW
Losses (cooling): 49 kW
Connections and regulators:
Wires: 4 terminals, starpoint connected in terminal box
Operation mode: Island mode with different generators in parallel
Regulators:
Voltage regulator: DECS 100
Electrical data: (acc. IEC)
Efficiencies: 110% 100% 75% 50% 25%
Power factor 0.8 95,39 95,61 95,73 95,23 93,16
Power factor 0.9 96,05 96,24 96,24 95,63 93,45
Power factor 1.0 96,7 96,86 96,75 96,03 93,73

Reactances and time constants

unsaturated saturated unsaturated saturated

xd 1.48 1.33 p.u. xq 0.74 0.73 p.u. Td0' 2.05 s Td0'' 0.02867 s
xd' 0.237 0.237 p.u. xq' 0.74 0.73 p.u. Td' 0.33 s Tq0' 0.3 s
xd'' 0.136 0.124 p.u. xq'' 0.136 0.136 p.u. Td'' 0.015 s Tq0'' 0.16324 s
x2 0.143 0.130 p.u. x0 0.041 0.037 p.u. Ta 0.045 s Tq' 0.3 s
x1s n.a. 0.074 p.u. Tq'' 0.03 s
Short circuit ratio saturated: 0.75 Zn 0.301 Ohm

Short circuit data:

Initial short circuit current (3-phase): Ik'' 10675 A
Max. peak current (3-phase): IS 27174 A
Sustained short circuit current: Ik 3971 A 3 x rated current for max.10 s
Initial short circuit torque: Mk2 176.0 kNm
Mk3 105.6 kNm
Max. faulty synchron moment: Mf 378.4 kNm
Rated kVA torque: MSN 16.79 kNm
Rated torque MN 15.11 kNm
Shaft torque MSh 15.70 kNm
Load application:
max. load application: 1001 kVA(corresponds to 63,29 % von 1582 kVA) Power: 1582 kVA
for Power factor 0.4 Power factor: 0.9
15% transient voltage drop transient voltage drop: -15.3 %
Remarks:
 Order specification for AvK-Alternators
FM 7.2-4
-technical-

~ Projekt checklist

Issued by: Sales department

Created by: Peter Heuvelman (jq205)

Released by: QuotationTool
Date: 03/05/12

CGT Order No.:

1 Spare parts order no.:
Others:
Customer: Wärtsilä Finland Oy
Revision no.: 1
Revision date: 03/05/12
Auxpac 2
2 Application / Project: Alternator type: DSG 99 K1/8 W

3 CGT quotation no.: 1-434-0000458-1 Quantity: 1

P-12.10579 FIN
4 Factory Project no.:
5 Customer Order no.: Mode of operation: Marine
6 Delivery Date:

7.1 Order Type:

7.2 Reference:
7.3 Valid drawing at order entry:
8 Marine / Ship operation:
9 Shipyard.:
10 New building no.:
11 Type of vessel:
12 Construction acc. to classification society: IEC 60034; DNV
13 Inspection acc. to classification society:
14 Mode of operation:
15 Supply type:
16

17 Rated data Rules, Standards

18 Output: 1582 kVA Standards: IEC 60034; DNV
19 P.F. Cos Phi: 0.90 R.I.S. Degree: VDE 0875 N
20 Voltage: 0.69 kV Insulation class: Class H
21 Current: 1323.7 A Temperature rise: F
22 Frequency: 60 Hz Ambient temperature: 45 ° C
23 Speed: 900 1/min Altitude at site: 0m

24 Technical data
27 Efficiency: see technical data sheet attached
28 Rated load at cos phi = 0.8: 95.61
29 Rated load at cos phi = 1: 96.86
30 Efficiency tolerance: acc. to VDE 0530, EN 60034
31 Reactances, time constants: see technical data sheet attached
32 Overspeed: 1,2 x rated speed for 2 min
33 Operating voltage range: Zone A according IEC 60034-1 (dU = +/-5%, df = +/-2%)
+/- 10% at no load for synchronisation, short term operation only
34 Operating frequency range: view line 33
35 Parallel operation: Island mode with different generators in parallel
36 Overload capability: 10 % for 1 h every 12 hours or 50 % for 30 sec.
37 3-phas. sustained short circuit current: 3 x rated current for max. 10 sec.

53 Design details, general

54 Design form: IMB 20 / IM 110x IM 1101

55 AvK project drawing:
59 Type of prime mover / Manufacturer and name of prime Diesel engine / Wärtsilä 8L20
mover:
62 Shaft end / -flange (DE): cylindrical shaft end
63 Rotation facing DE: counterclockwise
64 Surface treatment: Basic painting
Document: Revision: J dated 17.09.2004
7_2f04jE.xls Cummins Generator Technologies Germany GmbH 6/8
 Order specification for AvK-Alternators
FM 7.2-4
-technical-

65 Dynamic balancing: with half key at shaft end

70 Enclosure, Cooler

71 Enclosure alternator: IP44

72 Enclosure terminal box: IP20
73 Cooling type: IC 81W - watercooled

76 Cooler location: top

77 Coolant: Freshwater
78 Air inlet temperature inner circle: 53 ° C
83 Water inlet temperature: 38 ° C
84 Cooling water connections: Acc. to DIN 2633
86 Water pressure: Nominal pressure 6 bar, inspection pressure 9 bar
87 Cooler designed for: 1 x 100 % rated load
88 Cooler materials: Tubes CuNi10Fe / Cu
Plates CuZn38SnAl / steel zinc
Headers steel coated
Fins Al
89 Cooler equipment:
90 Leakage control / -filter ABAU-GL
91 Emergency flaps Emergency flaps IP20
92 Temperature detection 1 PT100 Air Outlet; 1 PT100 Air Inlet

98 Bearing arrangement + Lubrication

99 Bearing Design: Anti-Friction bearing

100 Calculated Lifetime: about 20.000 operating hours
101 Protection against shaft currents: Not insulated,

116 Terminal box + Accessories, Current transformers

117 Location main terminal box (seen on DE): Enlarged terminal box on top, integrated into cooler housing
119 Cable entry: Cable entry right
121 Cable gland plate: Drilled gland plate aluminium
122 Details, quantity + diameter of cables: Each phase: Cable qty. unknown; Type unknown; ODM unknown
N point: Cable qty. unknown; Type unknown; ODM unknown
123 Star point arrangement: 4 terminals, starpoint connected in terminal box
124 Location aux. terminal box (seen on DE):
126 Supplier of CT's: Transformers supplied by CGT
Transformers installed by CGT
127 Current transformers, starpoint side Core 1 Core 2 Core 3
128 - Primary current: 1500 A 1500 A
129 - Secondary current: 5A 5A
130 - Class: 10P10 10P10
131 - Burden: 15 VA 15 VA
132 - Standard test reports: Not applicable
134 Supplier of VTs: Transformers supplied by CGT
135 Voltage transformer(s) output side: Voltage transformer 3 phase LVDECS
136 - Transformation: 400/450/660/110 V - 40 VA
137 - Class 0.5
138 - Standard test reports for VTs: Not applicable

141 Voltage regulation system

142 Voltage regulator: DECS 100

Regulator function(s): Underexcitation limiter
Black Start Capability

148 Power supply of voltage regulator:: Aux. winding

149 Regulator location:

154 Instrumentation
155 Temperature detection stator windings: 6 PT100
156 Bearing temperature detection NDE-side: Single PT100
157 Bearing temperature detection DE-side: Single PT100
158 Temperature detection cooling air: 1 PT100 Air Outlet; 1 PT100 Air Inlet,
159 PT 100 design / connection: Standard design in 2-wire connection
162 Anti-condensation heater built-in: Supply voltage 230 V, 1-phase, 50/60 Hz, AC/DC
Power required 500 W

168 Works Tests

Document: Revision: J dated 17.09.2004
7_2f04jE.xls Cummins Generator Technologies Germany GmbH 7/8
 Order specification for AvK-Alternators
FM 7.2-4
-technical-

169 CGT Test: first generator: Type Test acc. to AvK Specification ING-PS-0005;
all other generators (if applicable):

170 Additional tests: not applicable

171 Works test witnessed by client: not applicable

174 Documentation / Dates:

175 Dimensional drawing: ca. 4 weeks after placement of order

177 Shaft drawing with moment of inertia: ca. 4 weeks after placement of order
178 Connection/terminal plan: ca. 6 weeks after placement of order
179 Drawings as DXF-File No
180 Operating instructions, Spare part lists: 2 weeks after works test
171 Test reports and Certificates: 2 weeks after works test
183 Number copies and language of documentation: 3 x German / 3 x English

190 Spare Parts, Tools

202 Additional details

203 Voltage matching: For Decs 100 and 200 the ratio of the sensing VTs
for generator and busbar voltage can be different.
Alternator is designed for inclinations of: 5°/7,5° Fore-and-Aft & 15°/22,5° Athwartships (stat./dyn.).
The altenatorshaft will be installed in parallel to the ships centerline.
Please contact the factory if alternator should be installed in athwarts direction.
Leistungsreduzierung des Generators auf 80% bei Ausfall Notfallbetrieb des Kühlers
Cross Current Compensation (CCC):
It must be ensured that CCC is de-activated when the mode
of regulation is changed from "AVR-mode" into "PF/VAR-mode".
Voltage matching: For Decs 100 and 200 the ratio of the sensing VTs
for generator and busbar voltage can be different.
Alternator is designed for inclinations of: 5°/7,5° Fore-and-Aft & 15°/22,5° Athwartships (stat./dyn.).
The altenatorshaft will be installed in parallel to the ships centerline.
Please contact the factory if alternator should be installed in athwarts direction.
Leistungsreduzierung des Generators auf 80% bei Ausfall Notfallbetrieb des Kühlers
Cross Current Compensation (CCC):
It must be ensured that CCC is de-activated when the mode
of regulation is changed from "AVR-mode" into "PF/VAR-mode".

Document: Revision: J dated 17.09.2004

7_2f04jE.xls Cummins Generator Technologies Germany GmbH 8/8
EC Declaration of Conformity

This synchronous a.c. generator is designed for incorporation into an electricity generating-set and fulfils all the relevant
provisions of the following EC Directive(s) when installed in accordance with the installation instructions contained in the
product documentation:
2006/95/EC Low Voltage Directive

2004/108/EC The EMC directive

2006/42/EC The Machinery Directive

and that the standards and/or technical specifications referenced below have been applied:

EN 61000-6-1:2007 Electromagnetic compatibility (EMC). Generic standards - Part 6-1: Immunity for residential,
commercial and light-industrial environments

EN 61000-6-2:2005 Electromagnetic compatibility (EMC). Generic standards - Part 6-2: Immunity for industrial
environments

EN 61000-6-4:2007 Electromagnetic compatibility (EMC). Generic standards - Part 6-4: Emission standard for
industrial environments

EN ISO 12100-1:2003 Safety of machinery - Basic concepts, general principles for design - Part 1: Basic
terminology, methodology

EN ISO 12100-1:2003 Safety of machinery - Basic concepts, general principles for design -Part 2: Technical
principles

EN ISO 14121-1:2007 Safety of machinery - Risk assessment - Part 1: Principles

EN 60034-1:2004 Rotating electrical machines - Part 1: Rating and performance

BS ISO 8528-3:2005 Reciprocating

p g internal combustion engine
g driven alternating
g current ggenerating
g sets - Part 3:
Alternating current generators for generating sets

BS 5000-3:2006 Rotating electrical machines of particular types or for particular applications - Part 3:
Generators to be driven by reciprocating internal combustion engines - Requirements for
resistance to vibration

The manufacturer’s authorised representative in the Community and person empowered to draw up this declaration and to
compile the relevant technical documentation, on behalf of the manufacturer is:

Dr. Andreas Biebighäuser

IPP Engineering Leader
Cummins Generator Technologies
Bunsenstrasse 17
85053 Ingolstadt
Germany

Signed: Date: 21st December 2009

DRAWING REF 450-16383-B

Description: DSG 99 M1-8 W Serial Number: 81 31663 A102, A202

Registered in England under Registration No. 441273.

Cummins Generator Technologies Ltd. Registered Office: Barnack Road, Stamford, Lincolnshire PE9 2NB, England
Contact Details
 TECHNICAL SUPPORT
PRODUCT REGION AFTERMARKET PARTS
Service / Warranty / Maintenance / Repair Quotes

Fiona Barkhouse +44 (0) 1780

EUROPE Horace Lenton 484742
MIDDLE EAST Tel +44 (0) 1780 484732 Shay Binder +44 (0) 1780 484744
MARKON
AFRICA Fax +44 (0) 1780 484104 Bruno Labinjan +44 (0) 1780 484798
STAMFORD
BALTIC STATES Mobile +44 (0)7500 607 597 Fax +44 (0) 1780 766074
AvK
NORDIC email: service- Mobile +44 (0)771 8339215
COUNTRIES engineers@[Link] email: [Link]@[Link]

Uwe Plep
GERMANY Anita Albrich
MARKON Tel +49 841 792 276
AUSTRIA Tel +49 841 791 192
STAMFORD Fax +49 841 791 195
HUNGARY Fax +49 841 791 238
AvK Mobile +49 171 683 7062
CZECH REPUBLIC email: [Link]@[Link]
email: [Link]@[Link]
Judy Smith
Americas Parts Team
NORTH AMERICA Louie Shar Toll Free Tel (USA and Central
MARKON SOUTH AMERICA Americas Service Team America) 1-800 367 2764 Ext. 5
STAMFORD MEXICO & Toll Free Tel (0) 800 367 2764 1 763 528 7301 Ext. 5
AvK CENTRAL AMERICA Toll Free Fax (0) 800 863 9234 Toll Free Fax (USA and Central
CANADA email: [Link]@[Link] America) 1-800 8963 9243
1763 574 5082
email: [Link]@[Link]
Theo Dragonas Theo Dragonas
MARKON AUSTRALIA Tel +61 (0) 296802299 Tel +61 (0) 296802299
STAMFORD NEW ZEALAND Fax +61 (0) 29680 1545 Fax +61 (0) 29680 1545
AvK SOUTH PACIFIC Mobile +61 (0) 412 886645 Mobile +61 (0) 412 886645
email: [Link]@[Link] email: [Link]@[Link]
V Devarajan V Devarajan
BANGLADESH
Tel. +912066246700 Tel. +912066246700
STAMFORD INDIA
Fax. +912066025331 Fax. +912066025331
AvK NEPAL
Mobile No. +91822395641 Mobile No. +91822395641
SRI LANKA
email: [Link]@[Link] email: [Link]@[Link]
Cynthia Chua (STAMFORD /
Richard Lee MARKON)
Tel.+65 6305 3158 Ext 158 Tel +65 6305 3169 Ext 169
Fax. +65 63053151/2 Fax. +65 6305 3151/2
Mobile. +65 97595606 email: [Link]@[Link]
email: [Link]@[Link] Cyril Ee (AvK)
SINGAPORE
Tel: +65 6305 3156 Ext 156
MALAYSIA
Chek Tay Fax. +65 6305 3151/2
PHILIPINES
MARKON Tel. +65 6305 3158 Ext 158 email: [Link]@[Link]
INDONESIA
STAMFORD Fax. +65 6305 3151/2 Ryan Xie
THAILAND
AvK Mobile: +65 91137511 Tel: +65 6305 3172 Ext 172
VIETNAM
email: [Link]@[Link] Fax: +65 6305 3151/2
JAPAN
Mobile: +65 9712 2009
KOREA
Mike Tami (Japan) email: [Link]@[Link]
Tel +81(0) 3 5735 0852 Mike Tami (Japan)
Fax. +81(0) 3 5735 0788 Tel +81 (0) 3 5735 0852
Mobile: +81 (0 )80 5075 2979 Fax. +81(0) 5735 0788
email: [Link]@[Link] Mobile: +81 (0) 80 5075 2979
email: [Link]@[Link]
 TECHNICAL SUPPORT
PRODUCT REGION AFTERMARKET PARTS
Service / Warranty / Maintenance / Repair Quotes

Jason Xu (Wuxi / Jiangsu)

Jason Xu (Wuxi / Jiangsu)
+86 510 8110 3027 or +86 510 8110 Ext 3027
Tel +86 510 8110 3027
Fax. +86 510 8521 7673
Fax. +86 510 8521-7673/7603
+86 510 8521 7603
Mobile: +86 139 5157 0763
MARKON Mobile: +86 139 5157 0763
email: [Link]@[Link]
STAMFORD CHINA email: [Link]@[Link]
AvK
Jianguo Xu
Jianguo Xu
Tel: +86 510 81103088
Tel: +86 510 81103088
Mobile +86 150 5221 9180
Mobile +86 150 5221 9180
email: [Link]@[Link]
email: [Link]@[Link]
Uwe Plep
Tel +49 841 792 276
Fax +49 841 791 195 Anita Albrich
ALL OTHER
Mobile +49 171 683 7062 Tel +49 841 791 192
AvK COUNTRIES
email: [Link]@[Link] Fax +49 841 791 103
WORLDWIDE
email: [Link]@[Link]
24 HOUR HELP DESK: +44 (0)1780 484732
Richard Hardy
Tel +44 (0) 1780 484771
Fax +44 (0) 1780 484104 Fiona Barkhouse
ALL OTHER Mobile +44 (0)7801 096641 Tel +44 (0) 1780 484742
MARKON
COUNTRIES email: service- Fax +44 (0) 1780 766074
STAMFORD
WORLDWIDE engineers@[Link] Mobile +44 (0)7718339215
email: [Link]@[Link]
24 HOUR HELP DESK: +44 (0)1780 484732
 Cummins Generator Technologies Worldwide Contact Details

HEAD OFFICE: Cummins Generator Technologies Ltd ITALY Cummins Generator Technologies Italia s.r.l.
UK Barnack Road Cummins Generator Technologies Italia s.r.l.
Stamford Via Giosuè Carducci 125
Lincolnshire PE9 2NB Sesto San Giovanni
Tel: +44 (0) 1780 484000 Milano – 20099
Fax: +44 (0) 1780 484100 Tel: +39 02 380 00714
Fax: +39 02 380 03664
Cummins Generator Technologies
Stamford Business Park
Cummins Generator Technologies
Ryhall Road JAPAN
Japan Liaison Office
Stamford
6-2-11, Higashikojiya, Ohta-Ku
Lincolnshire PE9 1XT
Tokyo 144-0033, Japan
Tel: +44 (0) 1780 484000
Tel: +81 (0)3 5735 0852
Fax: +44 (0) 1780 484107

Sole Distributor for Japan:

AUSTRALIA Cummins Generator Technologies Australia
Sawafuji Electric Co. Ltd
PO Box 6027
#3, Nitta Hayakawa-Cho, Ohta-Shi
Baulkham Hills Business Centre
Gunma Pref. 370-0344, Japan
Baulkham Hills NSW 2153
Tel: +81 (0)276 56 7043
Tel: +61 2 9680 2299
Fax: +81 (0)276 56 6075
Fax: +61 2 9680 1545

CANADA Cummins Generator Technologies Canada MEXICO Cummins Generator Technologies Mexico
2275 Lakeshore Blvd. West Av. Circuito Mexico No. 185
Etobicoke Parque Industrial 3 Naciones
Ontario M8V 3Y3 San Luis Potosi, SLP
Tel: +1 416 259 3741 C.P. 78395
Fax: +1 416 259 7167 Tel: +52 444 870 4400
Fax: +52 444 870 4471
CHINA Cummins Generator Technologies China
No. 2 Xin Rong Road NORWAY Cummins Generator Technologies Norway
New District, Osloveien 20
Wuxi Jiangsu 214028 1430 Ås Norway
Tel: +86 510 8110 8088 Tel:: +47 64 97 45 40
Fax: +86 510 81103277 Fax: +47 64 97 45 41

No. 11 Xiang Jiang Road ROMANIA Cummins Generator Technologies Romania

High-Technical Industrial Dev. Zone B-dul Decebal Nr. 116A
Wuxi Jiangsu 214028 200746 Craiova Dolj
Tel: +86 510 8110 3088 Tel: +40 351 443200
Fax: +86 510 8521 7673 Fax: +40 351 443201

Suite 1201, 12th Floor, SINGAPORE Cummins Generator Technologies Singapore

Metro Tower , 10 Toh Guan Road #05-04
30 TianYao Qiao Road , Singapore 608 838
Shanghai 200030 Tel: +65 6305 3150
Tel: +86 21 6085 2600 Fax: +65 6305 3151/2
Fax: +86 21 6085 2666

GERMANY Cummins Generator Technologies Germany GmbH USA Cummins Generator Technologies USA
Bunsenstraße 17 1400 73rd Ave N.E.
D-85053 Ingolstadt MC: OU1B
Tel: +49 (0) 8 41/7 92 - 0 Fridley, MN 55432
Fax: +49 (0) 8 41/7 92 - 250 Tel: +1 763 528 7301
Fax: +1 763 574 5082
INDIA Cummins Generator Technologies India
Godrej Eternia-C, B'Wing, 5th Floor, Wakdewadi,
Mumbai-Pune Road, Shivajinagar, Pune 411 005,
Tel.: +91 (0) 20 66246700
Fax: +91 (0) 20 66025331

C - 33, M.I.D.C. Ahmednagar 414 111

Tel.: +91 (0) 241 6603464 - 73
Fax: +91 (0) 241 2777494

G-06, M.I.D.C. Ranjangaon Ganapati,

Taluk Shirur, Dist. Pune 412 220
Tel.: +91 (0) 2138 399000
Fax: +91 (0) 2138 399098