product profile

Self-regulating brushless generators series DSG

C o n t e n ts:

1. 2. 3.

A p p lic a ti o n R a ti n g s D e fi n iti o n o f t h e a lt e r n a t o r 3.1 Basic technical data 3.2 Enclosure 3.3 Type of cooling 3.4 Design M e c h a n ic a l d e si g n 4.1 Design 4.2 Housing and stator 4.3 Rotor 4.4 End shields 4.5 Bearings 4.6 Terminal box P o w e r r e d u ci n g i n fl u e n c e s 5.1 Standard conditions 5.2 Relation between power and coolant temperature 5.3 Relation between power and installation altitude 5.4 Relation between power and power factor cos phi 5.5 M arine classification 5.6 Higher types of enclosure 5.6.1 Enclosure IP 4 3 5.6.2 Enclosure IPR 4 4 or IPR 5 4 5.6.3 Enclosure IP 4 4 or IP 5 4 El e ct ric a l p e r f o r m a n c e 6.1 O perating principle 6.1.1 Alternator 6.1.2 Voltage regulator 6.2 Self-excitation, de-excitation 6.2.1 Self-excitation 6.2.2 De-excitation 6.3 Voltage and frequency 6.3.1 Voltage setting range 6.3.2 Static voltage response 6.3.3 Transient voltage response 6.3.4 Voltage w aveform 6.4 Currents 6.4.1 Unbalanced loads 6.4.2 O verload 6.4.3 Short-circuit behaviour 6.5 N on-linear load 6.6 Emergency operation 6.6.1 Emergency manual control 6.6.2 Stand-by regulator P a r a ll e l o p e r a ti o n 7.1 G eneral 7.2 Parallel switching conditions 7.3 Start-up synchronisation at isolated parallel operation 7.4 Steady-state operation / load distribution 7.4.1 Voltage droop 7.4.2 Power factor regulation 7.5 M ains parallel operation 7.6 O scillations 7.7 N eutral current Pl a n n i n g g u i d e li n e s 8.1 N ominal capacity 8.2 Dynamic voltage variation 8.3 N on-linear load F a ct o r y t e sti n g 9.1 Standard tests 9.2 Special tests

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9.

A v K SE G c o m p e t e n c e i n e l ectricit y g e n e r a ti o n a n d p r o t ecti v e r e l a y i n g W hen it comes to electricity generation and protective relaying, AvK|SEG is your competent and reliable partner. We offer the quality and flexibility of a medium-sized, independent group of companies with a good mixture of experience and innovation. O perating globally, we are able to offer you custom-built engineering solutions as well as an extensive range of products. O ur product range extends

from individual protection devices to complete electrical fit-outs for power plants. AvK G ermany, with its factory in Ingolstadt and the site in Dreieich near Frankfurt, supplies synchronous machines and converters, while SE G Kempen specialises in plant engineering and devices for protection and other functions. Together we set standards and so influence electricity generation technology on an international scale. W e offer every performance level, regardless whether you require an individual device, an alternator or a turnkey system. O ur efficient customer service and advice centres throughout the world work energetically

to meet your needs, as we rely not only on continuity and quality in our technology solutions, but we also consider your satisfaction as equally important. The certification to DI N E N IS O 9 0 0 1 that AvK and SE G factories have underpins our high quality aspirations.

S e lf-r e g u l a ti n g b r u s h l e ss s y n c h r o n o u s a lt e r n a t o rs o f t h e s e ri e s t y p e D S G
1.
A p p lic a ti o n A p p lic a ti o n e x a m p l e s

The AvK alternators of series type DS G are the result of an advanced development process in which efficient manufacturing methods as well as many years experience in the applications of such synchronous alternators were utilised. This applies to the mechanical design, electrical characteristics and control engineering properties. The DS G series w as developed with particular regard to optimal operating efficiency, and to very favourable dynamic response in the event of load surges. Furthermore, for the magnetic circuit design, damper cage layout and winding design, special emphasis was laid on minimal reaction as a result of current harmonics on the voltage w aveform.

Th e f o ll o w i n g lists j u st so m e of th e a re a s w h e r e A v K s y nch ro n o us a lt e r n a t o rs f r o m t h e D S G s e ri e s 2 9 - 1 4 4 a r e use d in th e e n er g y s e ct o r : permanent power supply of stationary and maritime systems peak load operation in parallel with the mains emergency power supply for critical users, e.g. in power plants, industrial plants, hospitals, high-rise buildings on-board power supply for ships ship shaft generators, reversing machines diesel-electric drive for ships special power supplies for users who place high demands on supply-line quality frequency conversion, e.g. 5 0:6 0 Hz or 6 0:5 0 Hz Suitable for use in all kinds of drives: diesel engines, gas engines, gas, water and steam turbines as well as ship shaft generators.

Emergency power supply

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2.
R a ti n g s

Standard use ranges as per VDE 0 5 3 0, degree of protection IP 2 3, rated criteria according to Section 3.1 3 0 4,0 0 0 kVA, 4 0 0 / 2 3 1 V, 5 0 Hz, 1,5 0 0 rpm or 3 3 4,5 0 0 kVA, 4 5 0 / 2 6 0 V, 6 0 Hz, 1,8 0 0 rpm Furthermore, DS G alternators are available for all standard voltages to VDE 0 5 3 0 in the performance range given and also as special versions for specific voltages. In addition, the following rotational speeds are available, depending on power and size: at 5 0 Hz 1,0 0 0, 7 5 0, 6 0 0 and 5 0 0 rpm at 6 0 Hz 1,2 0 0, 9 0 0, 7 2 0 and 6 0 0 rpm Higher ratings up to approx. 6.5 MVA with 6 6 0 V or 6 9 0 V are possible on request.

C ombined heat and power station

O ffshore equipment

3.
D e fi n iti o n o f t h e a lt e r n a t o r

D e si g n e d i n a cco r d a nce w it h DI N -E N 6 0 0 3 4 , V DE 0 5 3 0 , IEC 3 4

3.1 B a sic t e c h n ic a l d a t a Rated power: Rated power factor: Rated voltage: Rated frequency: According to rated output values cos phi = 0.8 2 3 01 0 0 0 V 5 0 Hz or 6 0 Hz, Special frequencies on request 4 0C (VDE) 1,0 0 0 m above sea level (VDE) see 3.2 see 3.3 see 3.4 To ensure the alternators meet the desired requirements, conditions and specifications, deviations from this data and VDE 0 5 3 0 are possible on request. The alternators can be produced to all international standards such as BS 4 9 9 9, CIE 2 / 3, N E N 3 1 7 3, N EM A, etc., see Section 5.5.

C oolant temperature: Installation altitude: Degree of protection: Type of cooling: Design:

3.2 E n cl o s u r e IEC 3 4-5 DIN VDE 0 5 3 0-5 IP 2 3 provided as standard. Depending on size, higher types of enclosure e.g. IP 4 3, IPR 4 4, IPR 5 4, IP 4 4 and IP5 4 can be provided as required, see Section 5.6.

3.3 Ty p e o f c o o li n g IEC 3 4-6, DI N VDE 0 5 3 0-6 Provided as standard: IC 0 1 / IC 0 A 1. In the event of special protection requirements, the type of cooling will be adapted accordingly.

3.4 D e si g n IEC 3 4-7 DI N VDE 0 5 3 0-7 Sizes DS G 2 9 to DS G 7 4 are produced as standard in the designs IMB 3 4, IMB 2 4 and B2 / B5 or B5 / B1 6. Sizes DS G 8 6 to DS G 1 4 4 are available as standard in designs IMB 3, IMB 2 0 and IMB 1 6. O ther designs are possible. O n request, we will perform special feet dimensions in order to meet the requirements of the gen-set base frame.
B3 IMB 3 IM 1 0 0 1 B 5 / B 20 IMB 2 5 IM 2 0 0 1 / IM 1 1 0 1

B 3/B 5 IMB 3 5 IM 2 0 0 1

B 16 IMB 1 6 IM 1 3 0 5

B 20 IMB 2 0 IM 1 1 0 1

B2 IMB 2 IM 1 2 0 5

B 14 / B 20 IMB 2 4 IM 2 1 0 1

V1 IMV 1 IM 3 0 1 1

Design C ode I
DIN IEC 34 7

B3 IMB 3 IM 1001

B3 / B1 4 IMB 34 IM 2101

B3 / B5 IMB 35 IM 2001

B2 0 IMB 20 IM 11 0 1

B1 4 / B2 0 B5 / B2 0 IMB 24 IM 2101 IMB 25 IM

2001 / 1101

B2 IMB 2 IM 1205

B1 6 IMB 16 IM 1305

B2 / B5 _ _

B5 / B1 6 _ _

V1 IMV1 IM 3 0 11

Special design

C ode II
DIN IEC 34 7

DS G 29 52 DS G 62 74 DS G 8 6 114 DS G 1 2 5 14 4

DS G 2 9 4 3
1 4 5 6 7 8

Shaft Antifriction bearing, drive end Inner bearing cap End shield, drive end Fan Stator housing

9 10 11 12 13 14

M ain alternator stator M ain alternator rotor Exciter stator Exciter rotor End shield, non-drive end Antifriction bearing, non-drive end
15 16 17 18

C over Rectifier support Terminal box Terminal studs

4.
M e c h a n ic a l d e si g n

DS G 5 2 9 9
1 2 3 4 5 6

Shaft O uter bearing cap G rease regulation disc Antifriction bearing, drive end Inner bearing cap End shield, drive end

7 8 9 10 11 12

Fan Stator housing M ain alternator stator M ain alternator rotor Exciter stator Exciter rotor

13 14 15 16 17

End shield, non-drive end Antifriction bearing, non-drive end C over Rectifier support Terminal box Low voltage terminals

18

D S G 1 1 4 1 4 4 w it h a n tif ricti o n b e a ri n g s
1 2 3 4 5 6

Shaft O uter bearing cap G rease regulation disc Antifriction bearing, drive end Inner bearing cap End shield, drive end

7 8 9 10 11 12

Fan Stator housing M ain alternator stator M ain alternator rotor Exciter stator Exciter rotor

13 14 15 16 17 18

End shield, non-drive end Antifriction bearing, non-drive end Rectifier cover Rectifier support Terminal box Low voltage terminals

D S G 1 1 4 1 4 4 w it h sl e e v e b e a ri n g s
13 1 2 3 4 5 6

Exciter rotor End shield, non-drive end Sleeve bearing, non-drive end Rectifier cover Rectifier support Terminal box Low voltage terminals

Shaft Labyrinth seal Sleeve bearing, drive end Sleeve bearing shell O il ring M achine sealing

7 8 9 10 11 12

End shield, drive end Fan Stator housing M ain alternator stator M ain alternator rotor Exciter stator

14 15 16 17 18

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4.1 D e si g n The alternators consist of the main alternator as revolvingfield machine, the exciter machine as revolving armature machine, and the electronic voltage regulator. The components are constructed as a compact unit. The voltage regulator is provided built-in as standard in the main terminal box (DS G 2 9 5 2), in the nondrive end shield (DS G 6 2 9 9) or in a separate terminal box (DS G 1 1 4 1 4 4), or may be provided separately upon request for enclosed mounting into a switchboard. C ooling: At all machines, the cooling air is drawn in on the nondrive end, and blown out on the drive end by means of the shaft-mounted fan. O verspeed: In accordance with VDE 0 5 3 0, the alternators are designed to withstand a overspeed of 1.2 times the rated speed for 2 minutes. For higher runa w ay speeds, e.g. in the case of w ater turbines (1.8 x n N [rated speed]), the required design modifications will be made. C ircuit engineering precautions for protection of the system have to be arranged where required.

4.2 H o u si n g a n d st a t o r The stator laminated core consists of layers of low loss dynamo sheet metal, held by clamping rings or clamping plates. The stator as a whole forms a compact, stable unit consisting of stator laminated core and housing cover. The housing is constructed as an octagonal steel structure for the smaller units DSG 2 9 5 2, and in the case of the bigger machines, as a round welded construction. The feet of the DSG 2 9 9 9 models are welded to the housing, while in the case of the larger machines in the DSG 1 1 4 144 series, they are integrated into the end shields. The stator winding corresponds to temperature classification H as per DI N E N 6 0 0 3 4-1 or VDE 0 5 3 0-1. Fastening components and mechanically stable connections secure winding

overhangs and connectors against the dynamic stress generated by electrodynamic force.

4.3 Rotor The main rotor designed as salient pole execution consists of hydraulically compacted sheet metal or steel plates. The standard built-in damper cage is connected electrically in the pole shoes and between the poles. The winding of the main rotor is made of flat copper and is amply protected by suitably sized components against deformation caused by centrifugal force. The unidirectional fan is located at the drive end of the rotor. The exciter rotor consists of dynamo sheet metal, with the three-phase winding inserted into its slots. The rotating diodes in 6 pulse bridge connection are connected on the input side to the 3-phase winding of the exciter and on the output side to the field winding of the main machine. They are amply dimensioned in terms of voltage and current loads and also provided with a suppressor circuit.

The rotor windings comply with temperature class H of DI N E N 6 0 0 3 4-1 VDE 0 5 3 0-1. The shaft ends are cylindrical in types IMB 3 or IMB 2 0, with slot and key as per DI N 6 8 8 5 Sheet 1. The rotor is balanced with half key in accordance with VDE 0 5 3 0 / IEC 3 4-1 4 as standard. At alternators with shaft flange, e.g. design IM 1 2 0 5 (B2) or IM 1 3 0 5 (B1 6) or at machines with flexible steel discs, flanged shafts or steel discs will be adapted to the respective drive motor. O ther shaft designs or a second shaft end can be manufactured on request.

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4.4 En d shields Sizes DS G 2 9 to DS G 1 4 4 are equipped with welded or cast-iron end shields. DS G 2 9 9 9: Alternator feet attached in close proximity to the bearings and designed accordingly, guarantee an especially solid base. The drive end shield is produced from grey cast iron up to and including size DS G 6 2, and from DS G 7 4 is of a welded construction (standard in type B1 4). Flange bells with motor fixing dimensions to SAE standards can be attached to it. DS G 114 14 4: The alternators are fixed to the baseframe or foundation at the end shields, the alternator feet are integrated into the end shields. Both end shields are screwed to the stator housing and together form the complete alternator housing. The generally large intake areas cause a slight pressure loss and therefore a low cooling air flow velocity. In terms of filter use, this results in long maintenance intervals.

4.5 B e a ri n g s Up to and including size 4 3, pre-lubricated antifriction bearings with at least 2 5,0 0 0 hours operating life are built in. As an option, bearings allowing relubrication are available. From size DS G 5 2 up, relubrication antifriction bearings with a calculated life span for steady-state basic operation of at least 4 0,0 0 0 hours (up to size DS G 6 2) or 3 0,0 0 0 hours (from size DS G 7 4) are installed as standard. Up to size DS G 7 4, the antifriction bearings are generally prestressed, while the larger series machines contain prestressed bearings depending on the application and requirements. DSG alternators of twinbearing design are equipped with a fixed bearing and a floating bearing. The position of the fixed bearings and floating bearings depends on the size and the design factors. DS G alternators of singlebearing design have a floating bearing on the nondrive end. Sizes DS G 7 4 to DS G 1 4 4 can be equipped upon request and at additional cost with sleeve bearings flanged to the end shields. Depending on the operating conditions, forced oil lubrication or water-cooling can be required here.

Appropriate precautions protect all bearings during transport. In addition, for safety reasons, we provide sleeve bearing alternators without oil filling for transport.

4.6 Te r m i n a l b o x The main terminal box is performed according to enclosure IP 5 4. Depending on size, it may be on top (size DS G 2 9 to DS G 7 4), on the side if the customer prefers, on the top of the generator housing (DS G 8 6 to DS G 9 9), or on the side or above at the non-drive end shield with the desired cable outlet. For the series DS G 2 9 to DS G 3 6 all 6 winding ends are led to separate terminals, while for the larger product series, the neutral point is connected as standard to the winding overhang and is led to a common neutral terminal or neutral busbar. From size DS G 6 2, an open neutral point can be incorporated if required, together with an enlarged terminal box, for example for mounting of current trans-

formers for differential protection and measurements. In the case of built-in current transformers from AvK / K W K, a copper busbar constitutes the fourth terminal ( N ). The auxiliary and low voltage terminals are either on separate terminal strips in the main terminal box, in the end shield at the non-drive end, or in a separate terminal box on the stator housing, depending on alternator size. Voltage regulators,

Auxiliary terminal box DS G 1 1 4

temperature sensors, secondary outputs of current transformers, measuring lines for the exciter current, heating and suchlike can be connected here. The heating terminals which carry current when the unit is at rest are insulated for the protection of operating personnel.

M ain terminal box DS G 1 1 4

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5.
P o w e r r e d u ci n g i n fl u e n c e s

5.1 St a n d a r d c o n d iti o n s The unit ratings given are valid under VDE conditions, that is: C oolant temperature 4 0C , Installation altitude H 1 0 0 0 m above sea level, alternators of standard enclosure IP 2 3 and cooling type IC 0 1.

5.2 R e l a ti o n b e t w e e n p o w e r a n d co ol a nt te m p er a ture: Characteristic curve 5.2 The temperature limit of the winding is critical. A decrease in the coolant temperature (coolant temperature < 4 0C) leads to an increase in performance, while a temperature increase (coolant temperature > 4 0C) leads to a decrease in performance. The characteristic values of the particular alternator selected, for example reactances, are generally valid for the given rated power (S N ).

5.3 R e l a ti o n b e t w e e n po w er a nd i n st a ll a ti o n a ltit u d e : Characteristic curve 5.3 As both air density and therefore heat absorptivity decrease at higher altitudes, either the performance must be decreased or a larger generator must be chosen.

Relation between power and coolant temperature

Characteristic curve 5.2

Relation between power and installation altitude

Characteristic curve 5.3

[C]

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5.4 R e l a ti o n b e t w e e n po w er a nd po w er f a ct o r c o s p h i: Characteristic curve 5.4 The underexcited range of cos phi = 0 1 is limited during:

Relation between power and power factor cos phi

Characteristic curve 5.4

The overexcited range is limited by:

single operation by maintaining the rated voltage using the voltage regulator operation in parallel with the mains by stability against loss of synchronism

cos phi = 1 0.8 by the performance of the drive motor cos phi = 0.8 0 by the permissible rotor temperature rise.

underexcited overexcited Limitation by alternator Limitation by prime mover

5.5 M a ri n e cl a ssific a ti o n s As the coolant temperatures (CT) are higher and the permissible rises in temperature are lower than the specifications for land-based applications, the performance rating should be lowered, or a larger generator type chosen. The table opposite shows permissible rises in temperature; design and use according to temperature class H or F. For higher types of enclosure than IP 2 3 and other requirements, please send us a detailed inquiry. Temperature class Classification C ooling air temperature CT C 40 45 50 45 45 45 50 50 45 40 45 50 45 45 45 50 50 45 Temperature rise K 125 120 115 110 110 115 110 115 1 2 0 1) 105 100 90 90 90 90 90 95 1 0 0 1) Derating factor S N / STYP for series DS G 2 97 4 8 69 9 1 1 41 4 4 1 1 1 0.9 6 0.9 6 0.9 6 0.9 3 0.9 3 0.9 3 0.9 0 0.9 0 0.9 0 0.9 0 0.9 0 0.9 0 0.9 3 0.9 3 0.9 3 0.9 0 0.9 0 0.9 0 0.9 3 0.9 3 0.9 3 0.9 6 0.9 6 0.9 6 0.8 6 0.9 1 0.9 3 0.8 3 0.8 7 0.8 9 0.7 5 0.8 4 0.8 6 0.7 5 0.8 4 0.8 6 0.7 5 0.8 4 0.8 6 0.7 5 0.8 4 0.8 6 0.7 5 0.8 4 0.8 6 0.7 8 0.8 4 0.8 9 0.8 3 0.8 7 0.8 9

H VDE GL RI N A LR N KK DNV BV ABS MRS F VDE GL RI N A LR N KK DNV BV ABS MRS

1

) temperature rise reduced in order not to exceed VDE

13

5.6 Hig h er ty p es of e n cl o s u r e The design and electrical parameters are determined during the project stage. The degree of enclosure and the rated power are indicated on the rating plate. 5.6.1 E n cl o s u r e IP 4 3 Enclosure type IP 4 3 is possible for all sizes and requires the addition of air inlet filters, whose higher air resistance reduces the performance by about 5% 10% (depending on the size, rotational speed and air velocity). Temperature sensors in the generator which are to be connected to a control unit in the control panel warn against an unacceptable temperature rise in the winding when cleaning of the air filters is required.

5.6.2 E n cl o s u r e IPR 4 4 o r IPR 5 4 From size DSG 6 2, air intake and outlet ducts may be provided. As an extra advantage, in addition to the higher degree of enclosure, the necessary ventilation dissipates the heat through ducts from the installation area and also reduces the noise level. The position of the intake and outlet openings in the generator allows for the connection of supply and outlet air channels. The magnitude of the permissible pressure drops in the piping is to be agreed with the manufacturer.

5.6.3 E n cl o s u r e IP 4 4 o r IP 5 4 These types of enclosure are also possible for size DS G 6 2 and above and require the use of heat exchangers. For the alternator, the cooling air temperature emerging from the cooler and into the alternator is the deciding factor.

W ater-cooled heat exchangers: In general the heat exchangers are usually designed so that the temperature of the cooling air entering the alternator is 1 5 K above the w ater intake temperature. The change in performance is given in characteristic curve 5.2. There is no additional power reduction caused by increased air resistance in the cooling circuit.

Air-cooled heat exchangers: In this case, the cooling air temperature emerging from the cooler and entering the alternator is higher than the outside temperature by the temperature gradient in the heat exchanger. It is usually designed so that the cooling air going into the alternator is around 1 5 K higher than the air entering the cooler. The power reduction is given in characteristic curve 5.2. If the customer requires a more space-saving cooling system design, a reduction in performance may be necessary because of the resulting increase in air resistance. C areful evaluation and appropriate case by case type determination is recommended.

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6.
El e ct ric a l p e r f o r m a n c e

6.1 O p e r a ti n g p ri n ci p l e

6.1.1 A lt e r n a t o r In the smaller models, the G 1 stator windings are made from round wire, while those of the larger models are made from flat wire as preformed windings. The G 3 winding is also located in the main stator. From size DSG 5 2 up, the well-proportioned terminal box allows for the addition of supplementary controllers or modules. The G 1 rotor winding, made of section wire, is laid directly onto the insulated rotor laminated core. This gives an optimal copper filling factor and good mechanical strength. The strength of the impregnated coils is further increased by mechanical packing. The three-phase rotor winding of the G 2 stationary-field machine, and its field winding, are insulated like the windings of the main machine. High-quality multi-layer surface insulation materials are used to insulate the windings. This heat-resistant insulating system is suitable for the mechanical, electrical and climatic requirements of land and ship use. The G 3 auxiliary field winding supplies the field winding of the G 2 brushless three-phase a.c. exciter with

G1 G2 G3

M ain alternator Exciter machine Auxiliary winding

T6 R1

Voltage droop transformer Voltage adjuster

15

power via the actuator of the voltage regulator. The power generated in the 3-phase winding of the exciter rotor is rectified in a three-phase bridge connection consisting of silicon diodes and supplied to the rotor of the G 1 alternator. For varying load, the voltage of the main alternator is regulated by altering the excitation current in the G 2 winding using the transistor actuator of the voltage regulator. 6.1.2 V o lt a g e r e g u l a t o r An electronic voltage regulator is used for high voltage accuracy and excellent dynamic response. An auxiliary winding in the main stator supplies the regulator with power. In order to sense unequal phase voltages with unbalanced loads, the alternator voltage is measured at 3 phases for all regulator models. The voltage regulator keeps the terminal voltage at the main machine constant via the excitation current IK1 in the winding of the G 2 exciter. The following regulators are used as standard:

for sizes DSG 2 9 to 4 3, the C O SIMAT LC 1 regulator for sizes DS G 5 2 to 6 2, the C O SIMAT LC 2 regulator from size DS G 7 4 on, the C O SIMAT N + regulator.

internal and external alternator voltage set point adjustment PID gain control amplifier with freely adjustable P and I parameters underspeed protection (overproportional voltage drop at underfrequency) with LED display resistance against environmental effects due to encapsulated electronics long operating life due to high quality components compact design

long operating life due to high quality components compact design

6.1.2.3 C O SI M AT N + The C O SIMAT N + voltage regulator, used from size DSG 74 up, is a standardised component, subjected to endurance testing for electrical functioning and temperaturerise behaviour by the manufacturer before installation in the alternators. The capacity of the regulator is geared to the requirements of bigger machines. Apart from having those properties already described for the C O SIM AT LC 2 regulator, it is also possible to add supplementary regulators and modules to the C O SIM AT N + regulator. The control signals for the following functions are supplied via terminals on the C O SIM AT N +: power factor regulation / balancing reactive power regulation / balancing

If required, the C O SIMAT N + regulator can also be used for sizes DS G 2 9 to 6 2. W hen installing the C OSIMAT N + into machines of sizes DS G 2 9 to 4 3, the regulators and components are generally built in to the switchgear, while the terminal boxes of sizes DS G 5 2 to 6 2 offer sufficient space for a C O SIMAT N + and a maximum of 2 supplementary modules. Even for external assembly, the voltage regulators are always to be configured so that their power circuits have cooling air flowing freely through them. The low-pass filter required with harmonics load may be incorporated into the terminal box for all products in the range. 6.1.2.1 C O SI M AT LC 1 The C O SIM AT LC 1 is a compact voltage regulator for the regulation of threephase synchronous alternators in single operation. Essential features of the C O SIM AT LC 1 regulator are:

6.1.2.2 C O SI M AT LC 2 The C O SIM AT LC 2 is a compact voltage regulator for the regulation of threephase synchronous alternators in stand-alone and parallel operation. Essential features of the C O SIM AT LC 2 regulator are:

three-phase voltage measurement internal and external alternator voltage set point adjustment PID gain control amplifier with freely adjustable P and I control parameters parallel operation by reactive current-dependent voltage droop adjustable underspeed protection with LED display resistance against environmental effects due to encapsulated electronics

regulation to a mains interface point operating range extension automatic or manual stand-by changeover volts-per-Hertz regulation

three-phase voltage measurement

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stator current limiting excitation current limiting cable compensation

6.2.2 D e - e x cit a ti o n For de-excitation, the current in the G 2 exciter winding must be brought to 0. This can be done by disconnecting the connections UH1 and W H1 at the C OSIMAT LC 2, or by opening the bridge UH1-UH1 and W H1- W H1 on the C OSIMAT N + voltage regulator. In this way, the supply to the regulator is interrupted and the current in the exciter field falls to zero. For sizes 7 4 1 4 4, the de-excitation switch should be connected to the designated terminals (see wiring diagram legend), and not to the C O SIMAT N +, by use of a de-excitation relay. Encapsulated switches are to be used. The minimum load of the contacts must be > 5 V DC / 0.1A. The required rated load is 2 2 0 V A C / 1 0 A. Please note carefully the instructions in the appropriate wiring diagram. C aution: The excitation field electric circuit of G 2 must not be interrupted! After the deexcitation, the alternator produces a further residual volta ge of a pprox. 1 5% of U N . This value, p articularly for volta ges of over 4 0 0 V, can be a bove the permitted touch volta ge!

6.3 Vo lt a g e a n d f r e q u e nc y AvK alternators are built for 5 0 or 6 0 Hz operation at the voltages given in VDE 0530 and specifications from other countries. However, other voltages or frequencies are available on request.

More detailed descriptions of these devices are given separately. 6.2 S e lf- e x cit a ti o n , d e - e x cit a ti o n 6.2.1 S e lf- e x cit a ti o n Self-excitation without the use of external auxiliary means is achieved through permanent magnets in the frame of the exciter. In addition, excitation can be provided by an external voltage of approx. 1 0 V D C (positive pole on the I terminal). This voltage is applied to the terminals I1 K1 of the exciter during the run-up to rated speed. The external excitation must not be switched on when the machine is at rest.

6.3.1 V o lt a g e s e tti n g r a n g e The voltage adjustment provided as standard for alternators of sizes DS G 2 9 to DS G 4 3 is achieved by a rheostat located on the regulator. Alternators of size DS G 5 2 and up are provided as standard with a 5 0 0 setpoint adjuster. This is built in to the terminal box in units up to size 7 4, and is located in the control panel in the case of bigger units (also an option for sizes DS G 2 9 to DS G 7 4) for expediency reasons. The voltage is continuously adjustable within the range 1 0% of rated voltage. As per VDE 0 5 3 0, the control range is 5% of the rated voltage in no-load operation; it can be extended to 1 0% for operational testing of control panel components and for synchronisation. The resistance of the potentiometer cables

can be ignored for normal distances between assembly and control panel. The set point potentiometer is connected to the regulator terminals s / t. The connection lines of the set point potentiometer must be laid out separately as double-core shielded wires. For correct equipotential bonding, the shield must be connected to earth at either end or more often. The minimum wire size must be 0.7 5 mm2 . The optical shield covering must reach at least 8085%. For the operating range between no-load and full load, as per VDE 0 5 3 0 and IEC 3 4, the voltage range (0.9 51.0 5) x U N applies, with the given constraints.

6.3.2 St a tic v o lt a g e r e s p o n s e The voltage tolerance for all DS G alternators is 0.5% to 1% under the following conditions / disturbances:

no-load operation to rated load cos phi 0.1 1) 1 cold and w arm machines speed drop of approximately 3%.

) This concerns the regulation properties. The thermal rating for continuous operation is at cos phi = 0.8. The usual operational range is cos phi = 0.81.

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O scill o g r a m 1 / l o a d a p p lic a ti o n

6.3.3 Tr a n si e n t v o lt a g e resp o nse see Oscillogram 1 Application see O scillogram 2 Shedding The voltage change for sudden load variations depends on the leakage resistance voltage drop of alternator G 1. The magnetic circuit and the winding are optimally designed for slight transient voltage changes. External disturbances for transient voltage change are the relative current surge as well as the power factor. For example, during full load application with cos phi 0.8, the transient voltage drop is approximately 1 82 5%. The lower value applies to machines at 1 5 0 0 rpm, the higher value to low-speed machines of 5 0 0 rpm. W ith existing base load, the transient voltage change is slightly lower than that for a alternator operating at no load. The time constants of the alternator G 1, the exciter G 2, and the control system used as well as the dynamic speed decrease as an external influence determine the temporal path of the voltage. The amply dimensioned excitation system achieves short recovery times because the excess excitation

from the power supply equipment works up until the rated voltage is achieved. The recovery time is 0.50.8 seconds, depending on alternator size. 6.3.4 Vo lt a g e w a v e f o r m A sinusoidal voltage w aveform is produced by the geometry of the magnetic circuit and the choice of the winding factor of the stator winding. The usual definitions are:

Alternator DS G 8 6 L1-4, 2 8 4 0 kVA , 4 0 0 V, 5 0 H z , 1 5 0 0 rpm A pplication of 1 5 0 0 kVA cos = 0.1

O scill o g r a m 2 / l o a d s h e d d i n g

Telephone H armonic Factor THF

The requirements of VDE 0 5 3 0 are easily achieved.

total harmonic distortion

The harmonic content between Ph-Ph is 3% during no-load operation up to rated power and power factor cos phi = 0 . 11 at symmetric and linear loads. If required, a special winding arrangement reduces the total harmonic distortion to less than 3% and the single harmonics part to less than 2% even for the voltage w aveform between line and neutral. However, this results in a slight reduction in performance.

Alternator DS G 9 9 L1-6, 3 2 2 0 kVA , 4 5 0 V, 6 0 H z , 1 2 0 0 rpm Removal of 2 6 0 0 kVA , cos = 0.8

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6.4 C u r r e n ts 6.4.1 U n b a l a nce d lo a ds The electrical layout of the alternator also permits an unbalanced load. The following unbalanced loads, with no loading on the other phases, are allowed:

Size I / IN 29 36 43 52 62 74 86 99 114 125 144 1.0 1.0 0.9 0.7 5 0.6 0.6 0.6 0.6 0.6 0.6 0.6

this corresponds to I2 / I N 0.3 3 0.3 3 0.3 0.3 2 5 0.2 0.2 0.2 0.2 0.2 0.2 0.2

between the 3 phases. The voltage asymmetry will be about 1% per each 1 0% unbalanced load. If the other phases were also loaded with different currents, the magnitudes of the positive phase sequence system, negative sequence system, and zero phase sequence system must be analytically or graphically calculated, so that the actual alternator load may be determined. For the alternator, the current in any phase winding may not exceed the rated current and the ratio of the negative sequence system I2 to the rated current I N must remain less than 2 0%. AvK recommends limiting I 2 / I N to 0.0 8 in line with the relevant specifications for the protection of the entire system.

mately 1 0 seconds without the rated voltage dropping to an unacceptable level. This short-term overload capacity is available for starting currents of induction motors, for example.

current is a factor of 1.3 7 higher, and for a phaseto-earth fault a factor of 1.8 5 higher. In this w ay, protective devices can be co-ordinated to isolate the faulted system safely and selectively. The range IK 3 x I N is required for example in general by various classification societies. The associated exciter rating leads to a short-term voltage rise almost to ceiling voltage when the short-circuit is cleared. This (high) voltage rise may also occur during certain disturbances in the voltage control system. N ecessary me asures for the protection of consumers are provided for in the control p anel.

6.4.3 S h o r t-circ u it b e h a vio ur

The corresponding machine parameters determine the magnitude of the asymmetric short-circuit current. Depending on machine size, it decreases within 0.30.6 seconds to the sustained short-circuit current. The standard components are dimensioned so that the alternator can supply 2.5 to 4 times the rated current as sustained short circuit current for 3 seconds at a 3 phase terminal short circuit. W hen a 2 phase short circuit occurs, the sustained short-circuit

6.4.2 O v e rl o a d

I 2 = inverse current

C onsequently, the ratio of the negative sequence system I 2 to the rated current I N is clearly above the VDE requirements. Unbalanced loads cause voltage unbalance and additional losses that are particularly noticeable when there are temperature rises in the damper cage. Therefore, the load should be distributed on the system-side as symmetrically as possible

In accordance with VDE 0 5 3 0, the generators are dimensioned for 1.5 times the rated current for a duration of 3 0 seconds. To adapt to the requirements of internal combustion engines, an overload of 1.1 times the rated current can be maintained for 1h within 6h. The amply dimensioned excitation equipment permits a short-term overload of up to about 1.8 times the rated current for approxi-

O scill o g r a m / a s y m m e t ric s h o r t-circ u it c u r r e n t

Path of the short circuit current for 3 phase short circuit of an alternator DS G 1 2 5 K1-1 2, 2 7 4 0 kVA , 4 0 0 V, nominal current Inominal = 3,9 5 5 A with connected volta ge regulator

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7.
P a r a ll e l o p e r a ti o n

6.5 N o n li n e a r l o a d C onverters as consumers with non-linear currents cause harmonics in the voltage w aveform. In order to keep the losses occurring in the alternator and the system low and to guarantee the correct functioning of the connected electrical devices, the harmonic oscillation content of the voltage waveform should be as small as possible, see also Section 6.3.4. That presupposes a small sub-transient reactance xd. O ne of the w ays this can be achieved is by designing the damper cage in a particular w ay. W ith very high load part due to inverters, overdimensioning of the alternator may be necessary. This also requires a specific magnetic circuit design. This inevitably leads to an increase of the asymmetric short-circuit current. The measures to be considered for the alternator depend on the relative non linear load, the current harmonics brought about by the user, and the permissible harmonic voltage distortion.

It is advisable to consult the manufacturer in order to optimise the entire system. 6.6 E m e r g e n c y o p e r a ti o n W here stricter safety requirements exist, it is possible, in the event of failure of the electronic voltage regulator, to continue to operate the alternator using an emergency manual control or to change over to a stand-by regulator either manually or automatically. 6.6.1 Em e r g e ncy m a n u a l co ntrol The electrical power from the supply equipment is fed to the exciter winding I1 K1 of the exciter G 2 via an adjustable transformer with series-connected rectifier. M anual control of the correct exciter rating proves extremely difficult, especially in the case of inrush currents. Therefore, emergency manual control is only possible where there is almost constant load of a separate network or in the case of operation in parallel with the mains. To avoid consequential damage caused by operator error and because of the difficulty of manual operation, the alternator must be changed back to automatic voltage regulation as soon as possible.

6.6.2 St a n d - b y r e g u l a t o r The disadvantages of emergency manual control do not apply when a standby regulator is installed, because the alternator can operate as before after switchover to this regulator. The entire regulator unit main regulator, stand-by regulator, manual or automatic changeover unit must be built in to the switchgear.

7.1 G eneral Alternators from size DS G 5 2 and up are equipped as standard for parallel operation. The smaller sizes DS G 2 9 to DSG 4 3 can be upgraded accordingly. The parallel operation of the required number of units enables an optimal capacity utilisation and favourable operating efficiency. In addition, the operational reliability of the system increases since the other units can take over in the case of failure of one of the units after corresponding pre-setting.

7.2 P a r a ll e l s w itc h i n g c o n d iti o n s Alternators to be connected in parallel to each other or to the mains must fulfil the synchronisation conditions, i.e. be identical with regard to the following criteria: voltage frequency phase sequence phase position

Permissible tolerances before connection are:

voltage difference: 5% of U N frequency difference: 2% of f N

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The frequency tolerance applies to normal diesel generator sets. For operating mode with additional flywheel, a lower value is permissible. To avoid incorrect synchronisation (e.g. by unqualified operational personnel), a synchronisation control device should be fitted which shall only release the circuit breaker in the control panel if the synchronisation conditions described are met. Automatic synchronisation is generally recommended to avoid causing possible damage. After parallel connection, the active power load and reactive load distribution must be balanced. 7.3 St a r t- u p s y n c h r o n is a ti o n a t is o l a t e d p a r a ll e l o p e r a ti o n This function can only be used with similar types of machines, and requires simultaneous start-up of the diesel generator sets. The alternators are connected electrically to each other while at rest. As rotational speed increases, the alternators are excited and attempt to pull themselves into synchronisation. The excitation current during input of the initial excitation (1 2VD C) has to be limited so that the circulating currents

flowing in the UV W main lines until synchronisation occurs do not exceed the rated current. The exciter boosting current is usually dra wn from a series resistance and isolating diodes of a battery and fed to the exciter field connections I1 / K1, in parallel with the regulator connections. The resistance and the rated power of the series resistance depend on the battery voltage level and the no-load excitation of the alternator. In accordance with Section 6.2 De-excitation, regulator supply is interrupted during acceleration and released again when the rated speed is reached. The voltage produced by the regulator at terminals I1 K1 then exceeds the battery voltage. A blocking diode in the battery feed line prevents backflow into the battery, which can then be disconnected. Through the firing speed recognition, an inactive alternator may be disconnected. A supplementary current limiting regulator SR can be used for automatic limiting of the stator current.

7.4 Ste a d y -st a te o p e r a tio n / l o a d d ist ri b u ti o n

load distribution requires the same droop. The power factor dependence of the droop ensures that for parallel operation with the mains and during changes in the mains voltage, the apparent power changes in permissible limits. At the rated current, the droop is: 0.0% 1.3% 1.8% 3.0% for for for for cos cos cos cos phi phi phi phi = = = = 1 0.9 0.8 0

For active power load distribution, the rotational speed behaviour of the driving machine is responsible. For reactive load distribution, the voltage response of the alternators is responsible.

The following methods of reactive load distribution can be used: 7.4.1 V o lt a g e d r o o p After a synchronous alternator is connected in parallel, it is no longer possible to carry out voltage regulation because of the fixed mains voltage. Minor variations in the mains voltage would result in considerable alternator reactive currents. Therefore, for parallel operation, a droop transformer must be inserted in phase V of the alternator. W ith this current signal, a reactive-current dependent set point control is achieved in the voltage regulator. M ains voltage fluctuations of up to 2% can be equalised. Alternators from size DS G 5 2 up are fitted as standard with a current transformer for voltage droop. Smaller machines can be upgraded accordingly. Through the use of the droop, the terminal voltage is lowered depending on the reactive current. The power proportional reactive

Experience shows that stable parallel operation can be achieved when the droop in the plant is adjusted to 3% for nominal current and cos phi 0.1. For adaptation with other manufacturers products, the droop can be stepless adjusted between 0%6% of the nominal voltage.

7.4.2 P o w e r f a ct o r r e g u l a ti o n This process basically requires the use of the C O SIM AT N + base regulator (as standard from size DS G 7 4 up, as a retro-fit for smaller generators) and is used during operation in parallel

21

with the mains where the supply voltage fluctuates greatly. An additional regulator for cos phi regulation in the alternator or in the switchgear directly beside the base regulator controls the C osimat N + voltage regulator of the alternator for the purpose of maintaining the set power factor, i.e. the alternator voltage will follow the system voltage automatically. 7.5 M a i n s p a r a ll e l o p e r a ti o n As in most cases the mains has a much higher shortcircuit power than the alternators, the number of units running in parallel is irrelevant, i.e. there is no noticeable effect. Voltage fluctuation is thus nearly alw ays determined by the grid. For a variation in mains voltage U 2%, the droop in accordance with Section 7.4.1 applies. For a variation in mains voltage U 2%, a cos phi regulator in accordance with Section 7.4.2 is used, so that through the influence of the exciter, the alternator voltage automatically follows

the mains voltage and holds the set power factor constant during voltage fluctuations as well as during different alternator loads. If a specific power factor is required at the mains interface point, the cos phi regulator effective transformer must be configured at this point. However, it is also possible to use a specific mains coupling regulator Q PF- N K. So as not to overload the exciter circuit, an excitation current limiter is advisable. It limits the excitation current to the set value for the rated power for cos phi = 0.8. There is a further possibility of influencing the reactive power supply specifically by a reactive power regulator. W ith regard to permissible longer voltage and frequency variations, the specifications in VDE 0 5 3 0-1, Section 1 2.3, Figures 1 0 and 1 1 apply. If the voltage and frequency deviate from the rated values, there will alw ays be higher temperatures at constant rated power and therefore reduced durability of the winding and thus of the whole machine. Voltage rises cause higher iron temperatures in the main machine, which transfers to the winding. Voltage drops mean increased current and therefore increased heating of the windings. Since exceeding the temperature

permissible for the respective heat class always reduces the winding durability, prolonged operation on the limits of range A in DI N VDE 0 5 3 0-1 should be avoided. This can be assured if the machine is dimensioned and operated in accordance with the operating data specified at the project stage.

Since the winding and the neutral conductor are loaded thermally in this manner, this current must be reduced by a neutral choke. Alternatively, by using 2 / 3 chorded double-layer windings (standard with some 4 pole DSG models) a transient current can largely be avoided. If identical generators run in parallel in isolated operation, no neutral choke is generally necessary since the voltage w aveforms are identical between Ph-Mp.

7.6 O scill a ti o n s These periodic active and reactive power fluctuations are caused by irregular torque characteristics in the reciprocating internal combustion engines. To dampen these variations during parallel operation, a damper cage is built into all the DSG alternators as standard.

7.7 N e utr a l cu rr e nt For different voltage w aveforms of the alternators running in parallel as well as the voltage w aveforms of the grid, there are mainly 3rd order currents superimposed on the fundamental w ave in all 3 winding phases. These flow back through the neutral. The magnitude of these currents depends on the potential difference of the ripple voltage and the reactance of the alternator.

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8.
Pl a n n i n g g u i d e li n e s

9.
F a ct o r y t e sti n g

8.1 N o m i n a l c a p a cit y The nominal capacity results from the sum of all users considering the service factor. The necessary unit rating is determined after consideration of the power-reducing influences in accordance with Section 5.

bigger power steps can occur during the star to delta switchover. Slip ring motors: Start-up with armature resistance S=(1.3 1.6) x S N at cos phi 0.2 0.4 The inrush currents are small and mostly noncritical for dynamic voltage changes.

All DS G alternators are subjected to a full test run according to VDE guidelines. The tests are logged and the test reports made available to the customer.

Fi n a l i n s p e cti o n : G eneral design, testing of the components, wiring inspection, rating plate, circuit diagrams, identifications, anti-condensation heating, temperature sensors, etc.

9.1 St a n d a r d t e sts 1. 2. Measuring the cold resistances Measuring the residual voltage 9.2 S p e ci a l t e sts ( a t e x t r a c h a r g e) Further tests can be performed on request. Please ask if required. 1. 3. N o-load characteristic Determination of efficiency (summation of losses) N oise measurement

8.2 D y n a m ic v o lt a g e v a ri a ti o n A standard value used is U 2 0%. In this w ay, sufficient clearance is available for retaining voltage of normal contactors. Deviations from this value in the various specifications or as a result of further requirements must be considered on a case by case basis. For the determination of the dynamic voltage dip, the inrush current with power factor must be known. Inrush currents worthy of further investigation mainly occur while connecting induction motors. Suggested typical values are: Squirrel-cage motors: Direct on-line starting

Transformer connection: For transformer unit rating bigger than alternator unit rating, consultation with the factory is required. The high start-up rush of the transformers causes a load similar to a short-circuit. Depending on requirements, the inrush current should be attenuated by resistors or the transformer should be magnetised with rising generator excitation. This is generally advised in the case of unit-connected transformers. 8.3 N o n-li n e a r l o a d C aused by harmonics, increased losses occur in the alternator and the connected users. For clarification, the magnitude of the harmonics load, the current harmonic distortion as well as the permissible voltage harmonic distortion are to be confirmed to the manufacturer.

3. Voltage symmetry 4. Phase sequence test 5. Load characteristic with cos phi = 0.1 6. Range of the setpoint adjuster / voltage adjustment range 7. Voltage regulator 7.1 Adjustment of the voltage regulator 7.2 Underspeed protection adjustment 7.3 Parallel operation adjustment 8. Transient overload with cos phi = 0.1 or at short circuit 9. W inding test 1 0. O verspeed test at 1 2 0% nominal speed 1 1. High voltage test 1 2. Measurement of insulation resistances 1 3. Adjustment of additional voltage regulator modules

2. Short circuit characteristic

4. Temperature-rise test 5. 6. Load connection and load disconnection 7. H armonics content analysis

8. Peak short-circuit test 9. Sustained short-circuit current measurement 1 0. Vibration measurement (cardan-driven or at motor operation) 1 1. Rotor leakage test with rotor removed (inductor)

S=(5 6) x S N at

cos phi 0.2 0.4 Star delta connection S=(1.7 2.0) x S N at cos phi 0.2 0.4 Depending on the load torque during acceleration,

Su bject to tech nic a l m o dific a tio ns. 23

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AvK Deutschland GmbH & Co. KG Division Power Generation Bunsenstrae 17 D - 85053 Ingolstadt P.O. Box 10 06 51 D - 85006 Ingolstadt Phone: +49 (0) 8 41/7 92-0 Fax: +49 (0) 8 41/7 92-2 50 Homepage http://www.newage-avkseg.com e-mail: infoavkin@newage-avkseg.com Sales AvK Deutschland GmbH & Co. KG Dreieich branch Benzstrae 47-49 D - 63303 Dreieich P.O. Box 10 11 28 D - 63265 Dreieich Phone: +49 (0) 61 03/50 39-0 Fax: +49 (0) 61 03/50 39-40 Homepage http://www.newage-avkseg.com e-mail: infoavkdr@newage-avkseg.com

PM_ProdProf_DSG_08.02_01_GB