EMRI R10 Series Bedienungsanleitung

NHALTISCH

ELEKTROMOTORENWER

DESSAU GMB

KAD 30161/E

Edition 04/2010

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

Regulator-

operating instructions

for brushless three-phase synchronous generators

with regulator types

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

AEM

Anhaltische Elektromotorenwerk Dessau GmbH

Daheimstr. 18

D - 06842 Dessau - Roßlau

After-sales service

Tel.: 49 (0) 340 203 304 / 305

Fax: 49 (0) 340 203 311

email: aem@aemdessau.de

homepage: www.aemdessau.de

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ELEKTROMOTORENWERK

DESSAU GMBH

Page 2 of 24 AEM 30161  04/2010

General safety instructions

Notes for use

The notes used in the operating instructions have the following significance:

Danger!

Is used for activities that may cause considerable personal or material damage. Please

read and observe these notes carefully and act particularly cautiously in these cases.

Make other users aware of these notes concerning work safety.

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

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

equipment.

NOTE General type of notes

______________________________________________________________________________________

General safety instructions

Electrical generators for which these operating instructions were written are designed for use in commer-

cial installations. During operation, these generators have dangerous rotating and non-insulated voltage-

carrying parts. Serious personal and material damage may be caused by improper use, impermissible re-

moval of covers and protective installations, wrong handling and insufficient maintenance.

All work to be carried out on electrical generators such as assembly, connection or maintenance must

only be carried out while the system carries no voltage and is out of operation. Protect the system

against unintended reactivation.

These generators must only be transported, put up, connected, put into operation, maintained and operated by

specialized staff being trained to observe the relevant safety and installation regulations. All processes must be

checked by responsible specialized staff. These specialized staff must have been authorized for their activities

by the security system officer (for specialized staff regulations see DIN EN 50110-1 / DIN IEC 60364).

Operation by non-qualified staff is prohibited!

The person responsible for the installation must make sure

to have safety and operating instructions available and observing them;

to have all safety installations and personal safety equipment available;

that safety installations and personal safety equipment are used;

regulatory maintenance work is carried out;

the maintenance staff is immediately informed or the generator stopped if abnormal voltages, increased

temperatures, oscillations, noises etc. occur so that causes can be determined and damages avoided.

The manufacturer's liability is only maintained if the operating instructions are being observed at any

time!

NHALTISCH

ELEKTROMOTORENWER

DESSAU GMB

AEM 30161  04/2010 Page 3 of 24

Table of contents

1 Description of exciter system ...................................................................................................................... 4

1.1 Exciter system ...................................................................................................................................... 4

1.2 Voltage regulator .................................................................................................................................. 5

2 Behaviour during operation and notes on use ............................................................................................ 6

2.1 Excitation, de-excitation ....................................................................................................................... 6

2.2 Setting range for voltages, set-point adjuster ...................................................................................... 7

2.3 Voltage response ................................................................................................................................. 7

2.4 Radio interference suppression ........................................................................................................... 7

2.5 Operation .............................................................................................................................................. 8

2.5.1 Overload resistance ...................................................................................................................... 8

2.5.2 Operation with different temperatures of the cooling agent .......................................................... 8

2.5.3 Operation at power factors p.f. < 0.8 ............................................................................................ 8

2.5.4 Underspeed .................................................................................................................................. 8

2.6 Short-circuit response .......................................................................................................................... 8

2.7 Single operation ................................................................................................................................... 8

2.8 Parallel operation ................................................................................................................................. 8

2.8.1 Practical applications .................................................................................................................... 8

2.8.2 Neutral earthing current ................................................................................................................ 9

2.8.3 Synchronization ............................................................................................................................ 9

2.8.4 Parallel operation with static ......................................................................................................... 9

2.8.5 Parallel operation with compensating line .................................................................................. 10

2.8.6 Parallel network operation .......................................................................................................... 11

2.8.7 Electronic voltage adjustment ..................................................................................................... 11

2.9 Emergency operation without regulator ............................................................................................. 11

3 Power factor  regulation .......................................................................................................................... 11

3.1 General information ............................................................................................................................ 11

3.2 Description of functions ...................................................................................................................... 12

3.2.1 Function ...................................................................................................................................... 12

3.2.2 Modifications ............................................................................................................................... 12

3.3 Behaviour during operation and connecting instructions ................................................................... 12

3.3.1 No-load speed behaviour ............................................................................................................ 12

3.3.2 Behaviour under load .................................................................................................................. 12

3.4 Connecting instructions ...................................................................................................................... 13

3.5 Setting instructions ............................................................................................................................. 17

3.6 Adjustment at first startup .................................................................................................................. 18

3.7 Safety instructions for network breakdowns and isolated operation .................................................. 18

3.8 Notes on changing the p.f.-regulator .................................................................................................. 18

4 V/f-control .................................................................................................................................................. 18

4.1 V/f-control ........................................................................................................................................... 18

4.2 Setting instructions of regulator R10-KF ............................................................................................ 19

4.3 R10-KFG adjusting notes ................................................................................................................... 20

5 Troubleshooting ......................................................................................................................................... 20

5.1 Voltage problems ............................................................................................................................... 20

5.2 Checking and replacing the rectifier diode ......................................................................................... 21

5.3 Testing varistors ................................................................................................................................. 21

5.4 Replacing the regulator ...................................................................................................................... 21

5.5 Problems overview ............................................................................................................................. 21

5.6 Troubleshooting for p.f.-regulator R10-KC ......................................................................................... 24

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ELEKTROMOTORENWERK

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Page 4 of 24 AEM 30161  04/2010

1 Description of exciter system

1.1 Exciter system

Construction

The exciter system consists essentially of the following assembly groups:

choke [6]

current transformer [7]

stationary rectifier stack [8] with step-down resistor

electronic voltage regulator [9]

1 Stator winding

2 Rotor winding

3 Rotor winding of excitation machine

4 Stator winding of excitation machine

5 Rotating rectifier stack

6 Choke

7 Current transformer

8 Stationary rectifier stack

9 Electronic voltage regulator R10-Kx

10 Step-down resistance

11 Static current transformer

A Potentiometer voltage

B Potentiometer static

C Potentiometer stability

D External potentiometer voltage

Figure 1: Basic circuit diagram for

R10-Kx

All units are installed on a panel on the N side end shield. Exciter system and rotating rectifier stack can be

accessed by taking off the hood and opening the clamps or the screw connection.

For generator voltages higher 1 kV, an additional transformer with a secondary voltage of 400 V built in to

separate the AVR from the high-voltage side. The AVR is in a separate connection box. The exciter unit is

protected against unauthorized changes.

Working principle

The remanent voltage produced in the stator winding [1] of the generator causes a small current to flow

through the stator winding [4] of the exciter via choke [6] and rectifier stack [8] thus setting off self-excitation.

The choke [6] limits the exciter current of the exciter. The exact value depends on the air gap between core

and yoke of the choke. The required air gap is adjusted by adding insulating material.

NOTE For generator voltages higher 1 kV, an additional auxiliary winding is built in into the stator.

The voltage of this auxiliary winding serves as remanent voltage and supply the choke.

The load current flows through the current transformer [7]. When load is put on the generator, the secon-

dary current of the current transformer [7] is added to the choke current. After rectification in the stationary

rectifier stack [8]  a six-pulse bridge circuit  this alternating exciter current flows to the stator winding [4] of

the exciter. In order to protect the diodes against voltage surges, both the stationary rectifier stack [8] and the

rotating rectifier stack [5] are equipped with varistors.

Choke current and secondary current of the current transformer are adjusted such as to permanently main-

NHALTISCH

ELEKTROMOTORENWER

DESSAU GMB

AEM 30161  04/2010 Page 5 of 24

tain a generator voltage of approx. 10 % above the rated generator voltage while the generator rotates at its

rated speed and the voltage regulator is disconnected.

Every time the rated generator voltage is exceeded, the voltage regulator (AVR) [9] periodically switches on

step-down resistor that is located in parallel to the stator winding of the exciter [4]. This ensures that the

teminal voltage of the generator is kept at the value set by the set-point adjuster.

NOTE The chosen tappings of the winding to choke and current transformer have been optimally

adjusted to the generator in the manufacturer's test shop. You should therefore always con-

tact the manufacturer prior to making any changes.

1.2 Voltage regulator

Design

The voltage regulator is located in a sealed casing protected against dust and dirt. The casings contains the

potentiometers for setting the various regulator functions.

The potentiometers are equipped with a self-locking multi-speed mandrel drive that is secured against over-

speed by a sliding clutch. The setting range is approximately ± 10 revolutions.

The following regulator types are used:

R10-K Standard type providing voltage regulation and staticization for parallel operation. Designed with

smoothing capacitor CK and varistor.

R10-KAx In addition to the functions of the R10-K, also contains an analogue input via which the setpoint

voltage can be changed within a range of ± 10 % via an analogue signal input, either as 0  10

V signal (R10-KAU) or 4  20 mA signal (R10-KAI).

R10-KC In addition to the R10-K functions, this type contains a p.f.-regulation part. It can be used either

as a staticizing regulator or as a p.f.-regulator. Modifications of regulator R10-KC see section 3.

Power factor  regulation

R10-KF/

R10-KFG

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

age regulation.

NOTE The previously used regulator type R10 was functionally identical with the type R10-K but

has no capacitor CK or varistor. It can be replaced without exception by the other type; leave

terminal 12 unoccupied in this case.

All R10 series regulators have the same dimensions.

Connections

The voltage regulator is connected via spring-loaded terminal strips. The generator voltage is connected as

in figure 2 and the enclosed circuit diagram.

Figure 2: Connection for measuring and voltage supply

NOTE For generator voltages between 500 V and 1000 V, the regulator is connected to tappings of

the stator winding at approx. 400 V. For generator voltages higher 1 kV the AVR is con-

nected to a special measuring transformer (400 V).

NHALTISCHE

ELEKTROMOTORENWERK

DESSAU GMBH

Page 6 of 24 AEM 30161  04/2010

NOTE For current readings a static current transformer in phase W is used. Only some of the paral-

lel winding branches of the stator winding are put through the converter.

(observe when disassembling the exciter)

The connection of static current transformer to AVR have to be followed according to figure 3 under consid-

eration of section 2.7 and 2.8.

Figure 3: Connection for static current transformer

For all other connections see the circuit diagram of the generator.

2 Behaviour during operation and notes on use

Danger!

Only trained specialized staff are allowed to change settings using a suitable tool.

Observe during all setting and other work to be carried out on exciter and regulator

that all components carry network potential.

2.1 Excitation, de-excitation

Excitation

Self-excitation is provided by the remanent voltage.

Danger!

Measure the generator voltage during the excitation process.

Remove the external voltage source immediately, when the generator voltage rises.

Danger of inverse voltage!

If self-excitation of the generator does not work, excitation can be induced by briefly applying an external

voltage (6 or 12 V battery) to terminals X100:3 (battery plus), :4 (battery minus) in the terminal box of the

generator (figure 4).

Figure 4: Generator excitation and de-excitation circuit

De-excitation

Danger!

After de-excitation and while the drive is running, there is a residual voltage of up to

10 % of the network voltage on the generator terminals.

Special notice for generators with voltage more than 1 kV.

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ELEKTROMOTORENWER

DESSAU GMB

AEM 30161  04/2010 Page 7 of 24

Use a contactor or suitable switch to produce a short-circuit between terminals X100:3 and :4. Current load

on the contacts is < 10 A (figure 4).

2.2 Setting range for voltages, set-point adjuster

Use the "Spannung" potentiometer of the regulator or an external set-point adjuster to set the terminal volt-

age in a range of approx. ± 5 % of the rated value.

Danger!

Incorporate the external set-point adjuster in the protective measures against high

contact voltage.

You may connect an external set-point adjuster to terminals 6 and 8 on the regulator resp. X100:1 and

X100:2 in the terminal box of the generator (rotary resistor 2.5 k (to 5 k admissible), load limit approx.

1 W, test voltage > 2000 V). On the regulator, put jumper 7 - 8 to 6 - 7.

Figure 5: Connection for external set-point adjuster

Legend: Regler - Regulator Spannung - Voltage

Statik - Static Stabilität - Stability

NOTE We recommend using shielded cables!

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

2.3 Voltage response

Static voltage response

The voltage regulator maintains the set terminal voltage between no-load and rated current for power factors

in a range of p.f. = 0.5 (over-excited) to 1.0 with a tolerance value of under ± 1 %. This constant voltage

works for operation without staticization only. Valid speed increases of the generator drive are up to 105 % of

the rated speed between rated output and no-load operation.

Dynamic voltage response

Adding a rated load of a power factor of p.f. = 0.8 causes a voltage drop by approx. 12 to 15 %. Regulation

compensation takes about 0.3 to 0.5 sec. Both nominal values depend on the generator output and its num-

ber of poles. Greater additional loads are possible. However, in this case the voltage drops by up to 30 %.

Please contact the manufacturer for further information.

Voltage stability

The regulator is delivered with optimal settings for static and dynamic voltage response. If the output voltage

oscillates, slowly turn potentiometer "Stabilität" (figure 5) clockwise until the output voltage is stable again.

2.4 Radio interference suppression

Radio interference suppression corresponds to DIN EN 61000-6-4 unless any other arrangements were

made with the manufacturer.

NHALTISCHE

ELEKTROMOTORENWERK

DESSAU GMBH

Page 8 of 24 AEM 30161  04/2010

2.5 Operation

2.5.1 Overload resistance

Valid current overloads of the generator at p.f. = 0.5 are 10 % for an hour (once within 6 hours) or 50 % for

2 minutes. Brief overloads at motor starting operations are admissible. During overload conditions, the volt-

age tolerance of ± 1 % is no longer valid.

2.5.2 Operation with different temperatures of the cooling agent

The rated output stated on the type label is only valid in conjunction with the stated temperature of the cool-

ing agent. For other temperatures, the following output changes apply:

T / °C 30 35 40 45 50 55 60

PS / PN 1.06 1.03 1.00 0.96 0.92 0.88 0.84

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

2.5.3 Operation at power factors p.f. < 0.8

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

p.f. 0.7 0.6 0.5 0.4 0.0

PS / PN 0.94 0.89 0.85 0.82 0.80

2.5.4 Underspeed

Particular protection of the generator, the exciter or the regulator against underspeed of the generator drive

(e.g. during warm-up) is not required. Voltages are maintained constant down to speeds of approx. 90 % of

the rated speed. Below this value, the voltage is reduced approximately proportionally to the speed so that

every speed is admissible in no-load without time limitation.

2.6 Short-circuit response

The current surge (15 - 21 x IN) occurring during short-circuit conditions goes down to the sustained short-

circuit current after about 60 to 100 ms. Stable sustained short-circuit current of up to three times the rated

generator current is guaranteed for up to 5 sec. Please refer to the data sheet of the generator for all other

values. The sustained short-circuit current on one pole is approx. 5 - 6 x IN.

2.7 Single operation

To ensure single operation, the static current transformer can be deactivated by putting in a jumper between

terminals 4 - 5 (figure 3). This guarantees optimally constant voltage values for the generator.

NOTE Single operation is possible without limitations if there is no jumper between 4 and 5 (pa-

rallel operation circuit). In this case, voltage tolerances are determined by the static setting

and they are above 2 %.

2.8 Parallel operation

2.8.1 Practical applications

Brushless generators are designed for parallel operation. They are equipped with damper winding, connec-

tion for compensator circuit, static device and set-point voltage adjuster.

The following variations of parallel operation are possible:

Parallel operation with static with other generators as long as these provide parallel operation features

and if practically the same static voltage curves with falling characteristics can be set for all generators;

Parallel operation with compensator circuits of generators of the same type;

Parallel network operation either with regulator R10-K and non-regulated power factor or using regula-

tor R10-KC with power factor regulation.

For parallel operation of several generators, reactive power distribution as well as current and power output

variations must be within the range of applicable regulations. Prerequisites for this kind of operation are that

generator drives, and their speed governors in particular, are designed correspondingly providing the same P

range (speed drop between no-load and full load operation) or that a active power distribution proportional to

the power output is ensured by an automatic active power distribution installation.

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AEM 30161  04/2010 Page 9 of 24

Measure Effect during

single operation

Main effect during

parallel operation

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

Generator static -----------

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

Generator static -----------

Speed set point of drive Frequency Generator supply more active power

Speed set point of drive Frequency Generator supply less active power

NOTE Wrong distribution of active power (kW indicator not proportional to power output) is always

caused by the speed regulation of the generator drives.

Wrong distribution of reactive current (kW distribution o.k., different current distribution) is

caused by the voltage and static settings of the regulator.

2.8.2 Neutral earthing current

Connecting the generator star point to the star points of generators of another type or to the network earthed

neutral can cause compensation currents of mainly three times the network frequency to flow in the neutral

earth conductor that have been caused by different voltage curve lines of generators and mains network.

Neutral currents of up to 40 % of the rated current are admissible unless other values have been defined.

Reducing the neutral current can be achieved by inserting a special type of choke coil in the switching circuit

(please contact the manufacturer).

2.8.3 Synchronization

The generators can be synchronized by manual synchronization, automatically quick synchronization or

startup synchronization (please contact the manufacturer).

The following prerequisites must be observed for synchronization processes:

almost identical frequency of the two voltage systems f 0.2 Hz

almost identical terminal voltage of generator and mains network, admissible difference < 6 %

identical phase sequence of the two voltage systems

closing of switching contacts at a phase angle of < 15 degrees in relation to the zero crossover of the dif-

ference voltage of the two voltage systems.

ATTENTION! Wrong synchronization causes extremely high electrical and mechanical loads on the

generator which must be avoided under all circumstances.

Manual synchronization

Use the set-point adjuster to set the generator voltage to the network voltage. After setting smallest fre-

quency and phase differences possible by means of a synchronoscope, the generator can be switched on.

To avoid the occurrence of inverse power after switching on the generator, the generator frequency should

be about 0.2Hz above the network frequency.

Quick synchronization

Use an electronic synchronization device to adjust the system to smallest possible voltage, frequency and

phase differences automatically. The generator will be switched on considering that time element (switch) is

in zero crossover range of the difference voltage.

2.8.4 Parallel operation with static

ATTENTION! Check whether the jumper between terminals 4 and 5 of the regulator have been re-

moved.

Depending on current and power factor, the generator voltage characteristics have a decline. The voltage

drop can be set by the "Statik" potentiometer on the regulator (max. 8 % at p.f. = 0) (figure 5). The voltage

drop is increased by turning the potentiometer clockwise.

In the factory, the static is set to approx. 2 % (in relation to no-load voltage) at rated current and a power fac-

tor of p.f. = 0.8. Constant voltage during parallel operation depends on the static setting. If static setting and

static characteristics are nearly the same, the reactive power (in relation to the rated power of the corre-

sponding generator) is distributed proportionally.

ATTENTION! Make sure to do a generator adjustment before starting operation.

Only specialized staff must do these steps.

Check whether all drives have the same percentage value for speed drop between id-

le speed and full speed while in single operation.

Use the set-point adjuster to adjust the equal values of no-load voltages (±1 V) at all

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Page 10 of 24 AEM 30161  04/2010

generators. For this setting please use the same meter.

Put rated load at rated power factor on the generators in single operation possible and

check whether an almost identical voltage drop can be observed for all generators.

If you find larger differences, the static potentiometer must be readjusted. Static values of 2  3 % at rated

power and rated power factor are sufficient for stable parallel operation. This test must not be made with just

using active power as this renders the static inefficient.

NOTE Proceed as follows to make a supplementary test if only active power operation is possible

when changing the setting:

1. Connect the blue cable from phase U to W and the brown cable from phase V to phase

U on the choke terminal strip [6.1].

2. Put load on the generators.

3. The voltage drop corresponds to static setting at p.f. = 0.5 and normal switching condi-

tions.

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

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

smaller with p.f. = 0.8 therefore.

5. Reconnect all devices after the setup procedure.

Figure 6: Terminal connection for static setting at active power

2.8.5 Parallel operation with compensating line

Generators with the same exciter voltage can work in parallel if there is a compensating line (figure 7).

NOTE Put in jumper 4 - 5 on the voltage regulator.

Compensation for static potentiometer is not required. The compensating line is connected to terminals

X100:3 and :4 in the terminal box (make sure to connect only terminals of the same polarity). The max. com-

pensating current is 2 A. Provide auxiliary contacts on the generator power on / off switch to ensure that the

compensating line is only active during parallel operation. Under proportional active load distribution condi-

tions, the compensating line ensures an almost automatically proportional reactive load distribution.

ATTENTION! The open-circuit voltages of the generators must be checked and adjusted at no-load

speed of the drives prior to putting a system into operation.

In order to avoid measuring errors, measurements must be made with the same device.

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

Figure 7: Parallel operation with compensating line

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