(041)generator3phase_rev_1.pdf

FRV40-225-041-010

DESCRIPTION, OPERATION, INSTALLATION AND

MAINTENANCE INSTRUCTIONS

Generator, 3 Phase Synchronous Models: GSN 560 X4 – 1700KVA &

GSN 500 X4 – 1138 KVA

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

50-SPNA-1-00031

P

PUBLISHED BY DIRECTION OF NOAA

DanLe

REV 1

FRV40-225-041-010

DESCRIPTION, OPERATION, INSTALLATION AND

MAINTENANCE INSTRUCTIONS

Models: GSN 560 X4 – 1700KVA &

GSN 500 X4 – 1138 KVA

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

PUBLISHED BY DIRECTION OF NOAA

26 SEP 2005

REV 1

RECORD OF CHANGES

Change No.

Date Title and/or Brief Description Signature of Validating Officer

1 12/21/04 Made changes per NOAA recommendations.

APPROVAL AND PROCUREMENT RECORD PAGE

APPROVAL DATA FOR: FRV40-225-041-010

TITLE OF MANUAL: Generator, 3 Phase Synchronous

APPROVAL AUTHORITY: NOAA

Contract Ship Qty Of Building Number Applicability Manuals Yard

50-SPNA-1-00031 FRV40-225 2 EA Halter Marine Inc.

REMARKS:

CERTIFICATION: It is hereby certified that FRV40-225-041-010 to be provided under contract 50-SPNA- 1-00031 has been approved by the approval data shown above.

Date:________________

CHAND LLC

Mathews, LA 70375

CAGE CODE: 0DX54

VALIDATION PERFORMANCE

Title of Publication

Contractor Sub-Contractor(If Performing Validation)

Halter Marine Inc. Halter Marine Inc.

Contract No. (s) and Purchase Orders, If Applicable

Chapter Section Paragraph Date Check here if Validation Not validated Completed

Contents of this manual have been validated and certified to be applicable to the equipment furnished under the above procurement as specified for Validation.

Name & Authority of Validating Officer: Signature of Validating Officer:

GSN 560 X4 - 1700 kVA - 600 V GSN 500 X4 - 1138 kVA - 600 V

3-PHASE SYNCHRONOUS GENERATORS

INSTRUCTION MANUAL

No. ITC 2280

SUPPLIER : ASIRobicon S.p.A.

Electric Motors & Generators

MONFALCONE (GO) - ITALIA

ASIRobicon ORDER : 3.210.0003-04 ASIRobicon SERIAL NUMBER : 8006233-34-35-36

CUSTOMER : A.R.H. PITTSBURG

PLANT : CATERPILLAR NOAA

APPLICATION : DIESEL -GENERATOR SET

EDITION 2002

ITC 2280

Contents

Description

General Instructions

Commissioning Instructions

Fault diagnosis chart

Maintenance and Inspection Schedule

Rolling-contact Bearings

Rotating Rectifier

General cut view

Enclosures

Description

Type definition

The machines are internally ventilated brushless low-voltage synchronous machines

The machines have a shaft-mounted exciter on the in-board side of the non-drive end shield. The three-phase AC it generates is rectified and fed to the rotor winding of the main machine. The excitation current required for the exciter is provided by the PMG machine via an excitation control unit and voltage regulator. The PMG is placed on the side of the non-drive end shield, under the end-mounted cover.

Standards and regulations

The machines comply with the applicable IEC standards and with the requirements of

ABS.

The rated outputs apply to continuous running duty at a frequency of 60 Hz, at cooling-air temperature 50° C and at site altitude not exceeding 1000 m.a.s.l.

Degree of protection

The IEC 34-5 degree of protection of basic design machines is IP 23. Such machines are suitable for operation indoors.

Type of construction

The machines are provided with two bearing type of construction B20 according to IEC34- 7.

Cooling and ventilation

The machine uses self-ventilation by a shaft-mounted internal fan at the drive end.

Cooling air enters and cools the excitation control unit and subsequently the windings and core packs of the exciter and of the main machine before leaving the generator.

Stator frame and winding

The stator frame is of welded construction.

The stator core pack is fitted centrically in the stator frame and secured against rotation and displacement.

The stator windings are insulated to class F insulation requirements and may be round wire, bar or multiple bar windings. The insulating materials are chosen to suit the specific thermal stressing. Impregnation with synthetic resin renders all windings highly resistant to abrasive dust, oil, moisture or aggressive vapours and provides extra strength against short-circuit stresses.

Rotor and rotor winding

According to type of construction B20 the shafts of the machines have two journals and a standard cylindrical shaft extension.

The laminated rotor core of the main machine is pressed onto the shaft, clamped and secured against axial displacement, and carries the rotor winding (wire-wound winding) and the damper winding. The bars of the latter winding are firmly seated in closed slots of the rotor core and are welded or brazed to the end rings. The laminated rotor core of the exciter is pressed onto the shaft at the non-drive end and carries the three-phase exciter winding. The rectifier hub is arranged on the shaft between the rotor core packs of the main machine and the exciter. The complete rotor assemblies are dynamically balanced.

PMG

The PMG is accommodated on the side of non-drive end. The core of the PMG machine is made of both sides insulated electrical sheet steel. Permanent magnets are inserted in rotor slots, which are arranged around the core periphery.

Bearings

The machines are fitted with grease-lubricated rolling-contact bearings.

For a full description and special instructions, reference should be made to the supplementary instructions.

Terminal boxes

The electrical connections of the stator winding are made in the main terminal box.

Machines containing auxiliary circuits for functions such as anti-condensation heating, temperature monitoring etc. are fitted with auxiliary terminal boxes.

The terminal boxes at least comply with degree of protection IP 54 according to IEC 34-5.

The number, location and type of terminal boxes can be seen from the dimension drawing of the machine; the kind, circuit arrangement and connections of the main and auxiliary circuits are documented in the accompanying circuit diagrams.

General Instructions for brushless synchronous machines

Transport, storage

If a machine is not put into service immediately after arrival, store it in a dry, vibration-free room.

Installation

Mounting

The lubrication measures for normal bearings to be carried out before or during erection of the machines are contained in the additional instructions.

Install the machines in such a manner that the cooling air has free access and can escape unobstructed. Warm exhaust air must not be drawn in again. If the ventilation openings are covered by hooded louvre plates, the roofed-over slots should be faced downwards to maintain the degree of protection.

If there is a shaft block, remove it. The rotors are balanced dynamically. Align the machines carefully and accurately balance the elements to be fitted on the shaft to ensure smooth and vibration-free running. Place thin shims under the feet, if necessary, to prevent strain on the machines. Transmission elements must be fitted and removed only by means of a suitable tool.

The feather keys in the shaft extensions are locked prior to transport to prevent them from falling out.

Attention is invited to the measures necessary to prevent accidental touching of rotating parts (couplings, belt pulleys, etc.).

Examine the rating plate data to see that they agree with the power circuit to which the machine is to be connected. Select the size of the supply cable as required for the particular current rating. Connect the supply-cable conductors in accordance with the diagram shown in the terminal box.

The terminal markings specified in IEC 34-8 for three-phase machines are defined as follows, e.g.: U 1

Phase designation (U, V, W) U

Identification number of winding starts and ends or taps (if there is more than one connection per winding) 1

The unidirectional machines have an arrow plate indicating the direction of rotation. Note also any direction of rotation restrictions specified for the particular plant (non-reversing lock, for instance). In the case of synchronous machines the diagram instructions must be observed.

Before closing the terminal box, check to see that

- the interior of the terminal box is clean and free of cable residue;

- all terminal screws or bolts are firmly tightened;

- the minimum clearances in air are maintained (> 8mm for 500 V, > 14 mm for 1 kV, > 60 mm for 6 kV and > 85 mm for 10 kV; note any projecting wire ends);

- unused entries are closed off with the plugging elements firmly screwed in;

- for maintaining the degree of protection, all sealing surfaces of the terminal box are in order. If the seals comprise metal-to-metal joints only, these surfaces should be cleaned and thinly regreased.

Before starting and during operation, make sure that all relevant safety regulations are complied with.

Insulation testing

Before commissioning and after long periods of storage or standstill the insulation resistance of the windings to the frame must be measured with DC voltage. Do not discontinue measurement, before the final resistance value is indicated (with high-voltage machines, this process may take up to 1 minute).

The limit values for minimum insulation resistance and critical insulation resistance (for measurement at a winding temperature of 25°C) and for measuring voltage can be derived as follows depending on the rated voltage for the machine.

Limit values at rated voltage <2 kV:

Measuring voltage 500 V DC (min.100V DC) Minimum insulation resistance with new, cleaned or repaired winding 10 MΩ Critical specific insulation resistance after long periods of operation 0,5 MΩ/kV

Limit values at rated voltage ≥2 kV:

Measuring voltage 500 V DC (max.1000V DC) Minimum insulation resistance with new, cleaned or repaired winding 100 MΩ Critical specific insulation resistance after long periods of operation 5 MΩ/kV

Dry new windings have insulation resistance values between 100MΩ and 2000MΩ or higher. If the insulation resistance value is in the region of the minimum value, damp and/or dirt can be the cause. If the insulation resistance value falls below this minimum figure, the cause must be established and the winding dried. The insulation resistance for clean windings is largely dependent on temperature: for each 10 K rise in temperature it falls by half, i.e. with a temperature rise of 50 K (e.g. from 25°C to 75°C) it falls to about 1/30 of the initial value.

During operation the insulation resistance of the windings may decrease as result of environmental and operating conditions. The critical value of the insulation resistance at a winding temperature of 25°C can be calculated depending on the rated voltage by multiplying the latter (kV) by the specific critical resistance value in the table (MΩ/kV).

E.g.: critical resistance for rated voltage 600 V:

=0.6 kV x 0.5 MΩ/kV = 0.3 MΩ

If the measured insulation resistance value is above the calculated critical figure during operation, the machine can still operate further. When the measured value reaches or fall below this critical insulation resistance value, however, the windings must either be dried, or the rotor must be removed and the windings thoroughly cleaned and dried. If the measured value approaches the critical value, the resistance should subsequently be checked at appropriate short intervals.

Insulation resistance measurements on low-voltage machines with a measuring voltage of 1000 V are only permissible if the insulation resistance has previously been measured with a measuring voltage of a maximum of 500 V and has not fallen below the permitted values.

Operation

General remarks

Covers to prevent access to rotating and live parts and those required for proper air guidance (and thus effective cooling) should not be opened during operation.

Maintenance

Safety measures

Before starting any work on the machine, make sure that it has been isolated from the supply and that a safeguard is provided to prevent unintentional starting.

The cooling-air ducts which convey ambient air should be cleaned at regular intervals -depending on the degree of contamination - by blowing them out with oil-free compressed air. It suffices to clean the interior of totally enclosed fan-cooled machines during normal overhauls.

If dust or moisture has penetrated into the terminal compartment, carefully clean and dry the compartment, in particular the surfaces of the insulating parts. The seals and sealing surfaces should also be checked and the cause of faulty sealing remedied.

Dismantling, assembling

Before forcing off a part, it is recommended that two of the upper fixing screws be replaced by longer screws or threaded bolts which will support the part after it has been forced off the centering recess.

Spare parts

When ordering spare parts, please state the type and serial number as shown on the data plate in addition to the exact designations of the parts required.

Commissioning Instructions for brushless synchronous machines

The following instructions are a summary of the detailed information given in the supplementary instructions.

Preparation

The following checks and tests should be performed after initial installation and subsequent overhauls:

- machines correctly aligned,

- minimum insulation resistance of the windings satisfactory (also check after extended shutdowns),

- specified direction of rotation of machine agrees with that of the drive,

- cooling air flow not obstructed,

- rotor revolves freely without touching,

- all fixing bolts, fastening devices and electrical connections tight,

- earthing and potential-equalizing connections satisfactory,

- bearings properly lubricated according to type and supplementary instructions,

- no bridging of any bearing insulation fitted,

- any auxiliary devices fitted (e.g. temperature monitoring instruments in windings and bearings, anti-condensation heaters, etc.) properly connected and serviceable,

- all protection measures against contact with moving or live parts properly implemented.

Start up

The following commissioning procedure is recommended:

- run up the generator slowly,

- check for mechanical noise or vibration in the bearings and end-shields,

- if the mechanical running of the generator is satisfactory, start excitation gradually (see supplementary instructions );

if the running smoothness deteriorates it indicates a magnetic fault such as uneven air gap or inter turn short-circuit, -when the generator is running satisfactorily it can be synchronized with the supply system and loaded; check the running smoothness and record the readings of voltage, current, output and excitation; if possible, also record the corresponding values from the prime mover, -monitor and record the temperatures of the bearings, windings, etc. until steady state is reached.

Shutting down

The most important recommendation is to disconnect the machine with the stator current as low as possible. Slow-down can be braked or unbraked. Switch on the anti-condensation heaters if this is not done automatically as recommended.

Fault diagnosis chart for mechanical parts of synchronous machines

General

The following chart lists general faults due to mechanical factors. Bearing faults are dealt with in the relevant supplementary instructions for bearings.

Fault Possible cause Remedy A B C D Air supply obstructed, filter dirty, wrong direction of rotation Check air ducts, clean filter, change fan

Revolving parts rubbing Ascertain cause, re-align Rotor unbalanced Uncouple rotor and re balance Unbalance in coupled machine Re balance coupled machine Rotor out of true, shaft distorted Discuss with factory Misalignment Re-align machine, check for misalignment when hot, check coupling Interference from gearing Check gearing Resonance with foundation Stiffen foundation after consulting factory Changes in foundation Ascertain cause of changes and eliminate.

Re-align machine

Impulses from coupled machine Check coupled machine Overload Reduce load Insufficient cooler capacity Clean cooler and air ducts.

A - Rubbing noise B - Excessive temperature C - Radial oscillation D - Axial oscillation

Maintenance and Inspection Schedule for brushless synchronous machines

General

Careful maintenance and inspection allow any faults to be detected and corrected at any early stage before they are able to develop into serious damage. Therefore, they help to preserve the value of the machine, prevent costly outages and increase its reliability and availability.

Since the conditions under which the machines are required to operate can vary widely, it is only possible in maintenance and inspection schedules, to recommend maximum intervals between inspections for normal conditions. Experience gained at the actual place of installation must be used subsequently to adjust the inspection intervals when necessary to take account of factors such as contamination, frequency of start-up, load, etc. It is recommended, therefore, that the accessible parts of the machine be inspected visually about 500 hours after commissioning.

Furthermore, the inspection intervals given in the maintenance schedules presuppose no operating disturbances. If any disturbances or unusual operating conditions occur (e.g.

overload, short-circuit, incorrect synchronizing, machine runaway, etc.) which cause electrical or mechanical over-stressing of the machine, the appropriate inspections must be carried out immediately.

If supplier engineers are not called upon to carry out the inspection work it should only be entrusted to trained personnel who have had adequate experience on large electrical machines. We suggest that such personnel be instructed by a supplier engineer during his presence for installation, commissioning or inspections. Repair work which goes beyond normal maintenance or inspection procedures, and any subsequent modifications, etc. should always be carried out by supplier engineers.

The relevant safety and protection measures demanded by local regulations must be implemented when carrying out inspection and maintenance work.

First inspection

The first inspection should be made after approx. 500 hours. It should then be determined on the basis of the rate of fouling, whether the cooling air ducts will require cleaning before the second inspection normally carried out after approx. 1 year.

The following checks should also be carried out:

- running smoothness of machine satisfactory,

- rotor alignment within tolerances,

- no subsidence or cracks in the foundation,

- all fixing bolts of mechanical and electrical joints tight,

- insulation resistance of windings satisfactory (compare with previous reading or the minimum values given in the appendix "General instructions" and record),

- no bridging of any bearing insulation,

- windings, connection leads and insulating parts in satisfactory condition and no discolouration.

Any excessive deviations or changes ascertained during the checks must be corrected immediately. Damaged or used locking elements from released bolted joints must be renewed.

Subsequent inspections

Unless a shorter interval has occurred with the first inspection, the second inspection should be carried out after approx. 1000 switching operations or after approx. 1 year at the latest. Subsequent inspection intervals should then be set depending upon contamination of the cooling air ducts.

Information on regreasing, etc. is given on the lubrication instruction plate on the machine or in the supplementary instructions for bearings.

The checks stated for the first inspection should be repeated during subsequent inspections, and all cooling air ducts should be cleaned with dry compressed air.

For normal inspections it is generally not necessary to dismantle the machines.

Dismantling only becomes necessary when the bearings are renewed. It should then also be checked that the slot wedges in the cores are tight.

After reassembly, follow the recommendation in the supplementary "Commissioning instructions".

Rolling - contact Bearings

Electrical machines fitted with rolling-contact bearings are subject to the following instructions supplementing and modifying the operating instructions of the machine.

Installation

Mounting The locating bearings are deep-groove ball bearings for horizontally mounted machines.

The floating bearings are deep-groove ball bearings, the axial play is compensated by means of compression springs.

Examples for bearing combination

The mode, of bearing is favorably chosen as for direction and size of load (type of construction, forces acting on the shaft) and therefore it should not he changed. The permissible values of axial and radial forces may be taken from the list of machine or may be inquired.

The machines should operate in only one type of construction as shown the rating plate, because another type of construction required perhaps further measures in addition to a modification of the model of bearing. Always in this case an inquiry is necessary.

Lubrication

The bearings should be relubricated (see "Maintenance") if the time between delivery and commissioning of the machines is more than 4 years, assuming that they have been stored in favourable conditions (i. e. in a dry, dust and vibration-free room) or more than 2 years if they have been stored in unfavourable conditions.

Floating and Locating bearing (examples, delivered design may deviate in details)

1 V ring 1) 2 Outer bearing cap 1) 3 Lubricating nipple 4 Circlip 1) 5 Grease slinger 1) 7 Inner bearing cap with felt sealing rings 1) 8 Deep-groove ball bearing (floating bearing) 9 Compression spring 1) 10 Inner bearing cap with felt sealing rings 2) 12 Grease slinger 2) 13 Circlip 2) 14 Outer bearing cap 2) 15 V ring 16 Deep-groove hall bearing (locating bearing)

1) floating bearing side

2) locating bearing side

Maintenance

Lubrication

For the initial lubrication of bearings, a lubricating grease DIN 51825-K3k with lithium soap as thickener and with mineral oil as basic oil is usually used. The type of thickener and the basic oil are not stipulated in DIN 51825 and must always be stated additionally.

If special operating conditions necessitating a different kind of grease were known when the machines were ordered, then the grease definition (type of grease, thickener and basic oil) can be taken from the data plate.

Besides the definition of grease used in the case of machines with regreasable bearings, the regreasing interval and the necessary amount are given on the data plate.

It is recommended to follow the greasing instructions exactly. Mixing greases of different thickeners and basic oils reduces the quality and is therefore to be avoided. Only in special cases should deviations be made from the usual greasing data. The regreasing intervals should be shortened, for instance, if the machines are operated at coolant temperatures higher than originally allowed for, if corrosive vapours occur or extremely heavy contamination is present.

Clean the greasing nipple and insert the grease stipulated on the data plate using a grease gun. At the same time the shaft should be rotated in order that the new grease is distributed uniformly in the bearing. After regreasing, the bearing temperature will rise by a few degrees and will drop to the normal value when the grease has reached its normal service viscosity and the excess grease has been forced out of the bearing.

The old grease from several regreasing operations gathers in the space inside the outer bearing caps. Remove the old grease when overhauling the machines.

Dismantling assembling

It is recommended that new rolling bearings be installed as follows: Heat the ball bearings or the inner ring of the roller bearings in oil or air to a temperature of approx. 80 °C and slip them onto the shaft. Heavy blows may damage the bearings and must be avoided.

Care must be taken during assembly to see that the sealing rings are fitted properly (see sketches).

When fitting shaft seal rings (V-rings), the correct axial position of the V-rings is attained when the bearing cap end face and outside edge of the V-ring are flush. It is recommended using an appropriate assembly aid for this.

Before new felt sealing rings are fitted into the bearing caps, they must first be impregnated in 80 °C hot highviscosity oil (lubricating oil DIN 51517-C100). They should be dimensioned so that the shaft slides easily in yet is also well enclosed by them.

Fiting instructions for shaft seal rings

Location faults

The following table helps to trace and remove the cause of faults.

It is partly difficult to be found the damages of bearings. In the case of doubt it is recommended to renew the bearings.

Defects Causes Bearing overheats Bearing screeches

Bearing knocks

Remedy

Felt sealing rings pressing on shaft

Fit rings better into groves or replace them

Strain applied from coupling

Improve aligment of machine

Excessive belt tension Reduce belt tension Bearing contaminated Clear or replace bearing, inspect seals Ambient temperature higher than 400 C

Use special high temperature grease

Lubrication insufficient Lubricate to instructions Bearing canted Check mounting conditions, install outer ring with lighter fit To little bearing play Fit bearing with larger play Bearing corroded Replace bearing, inspect seals Scratches on raceways Replace bearing Scoring Replace bearing, avoid vibration while a standstill Excessive bearing play Install bearing with smaller play

Spare parts

When ordering spare parts in the manufacturer's work, state the type and the serial number of the machine. When ordering spare bearings, state the bearing marking as well as the symbol placed behind for the bearing type. Both markings may be read from the installed bearing or may be taken from the list in case of standard-type machines.

Rotating rectifier

Maintenance

General

For dismantling and assembling, the following specific instructions apply in addition to the general notes and the supplementary instructions.

Replacing the rectifier diodes

The rectifier and varistor modules are fixed to a hub with radial screws. Faulty modules can be replaced as follows. After undoing the fixing screws and the contact screws, withdraw the faulty modules in an axial direction from under the connector rings. Apply a thin coat of vaseline to the contacting surfaces of the connector rings and of the replacement modules. Fit the modules with the correct polarity (negative pole towards the drive end), apply Loctite to the fixing and contact screws and tighten them using a torque spanner.

Specified tightening torque

- of the fixing screws: 4.5 Nm to 5.5 Nm

- of the contact screws: from 2.5 Nm to 3.5 Nm.

Replacing varistor block

The varistors provided for the protection of the rectifier diodes take the form of modules for radial mounting to the rectifier hub. To replace the radially mounted varistor modules, proceed as described for the rectifier modules under "Replacing the rectifier diodes".

ITC

G eneral cut view

Enclosures

For ASIRobicon order : 3.210.0003 serial numbers : 8006233-34

Overall dimension

Shaft for torsional torque analysis

Connection diagram

Name plates

For ASIRobicon order : 3.210.0004 serial numbers : 8006235-36

Overall dimension

Shaft for torsional torque analysis

Connection diagram

Name plates..........................................................................................................96 7483

Excitation

Excitation system panel

Instruction manual BASLER SSR125-12

Instruction manual BASLER MVC 236

SSR Series Voltage Regulators

SX-6

9-92

Class 200 Equipment

SSR SERIES

VOLTAGE REGULATORS

ROUTE 143, BOX 269 HIGHLAND, ILLINOIS 62249, U.S.A. PHONE 618-654-2341 FAX 618-654-2351

APPLICATION:

The SSR Series Voltage Regulators provide reliable, high performance voltage regula-tion for 50/60 and 400 Hz brushless generators requiring 12A of excitation at either 32, 63 or 125 Vdc. The SSR Voltage Regulator receives its power for precise voltage regulation from a PMG (Permanent Magnet Generator), self excitation from the genera-tor line, or other AC sources. Supplied with each regulator is a spike suppression chassis for PMG and power isolation transformer applications.

FEATURES:

• Regulation accuracy better than ±0.25%

• Adjustable frequency compensation

• Selectable single or three-phase sensing

• Built-in parallel droop or cross current compensation

• Overexcitation shutdown

• Solid state voltage buildup

• EMI suppression built-in

• Modular replaceable parts for ease of service

• Applicable for 50, 60 or 400 Hz systems

• Compatible with single phase PMG generator

(50 to 240 Hz power input range)

• Spike suppression chassis

• Compatible with a wide range of accessory control and protective devices

• CSA approved – CSA File Number LR 23131

DESCRIPTION AND

SPECIFICATIONS

this page

FEATURES AND

APPLICATIONS

ACCESSORIES AND

INTERCONNECTS

OUTLINE AND

DIMENSIONS

ADDITIONAL INFORMATION

Request Publication 9185900990

The SSR Voltage regulator is completely solid state and uses state-of-the-art circuitry to provide high performance with a wide range of standard features. Voltage is internally or remotely adjustable, with single-phase or three-phase cus-tomer selectable sensing over a wide range. The SSR has a variable frequency compensated operating characteristic (See Figures 1 and 2).

During start-up, the solid state voltage build-up circuit operates from generator output residual voltages as low as 5% of nominal. The built-in over-excitation limiting removes the output power if the exciter field voltage exceeds a predetermined level. After removing field power, the regulator maintains its shutdown state until the

OUTPUT POWER:

DESCRIPTION

SPECIFICATIONS

generator has decreased below 5% of nominal.

The SSR may also be used with generator equipped with single-phase permanent magnet generators (PMG) for excitation power. With this application or applications where a power isolation transformer is incorporated, use suppression chassis P/N 9261500100 or P/N 9261500101, supplied with each regulator.

Maintenance of the SSR voltage regulator is simplified by the use of replaceable modules. Sensitive electronic equipment is protected from the effects of moisture, contaminants, vibration, and shock, by encapsulation.

SSR Continuous Forcing Continuous Forcing Model Voltage* Voltage* Current Current

SSR 32-12 32 Vdc 50Vdc 12Adc 20Adc

SSR 63-12 63Vdc 100Vdc 12Adc 20Adc

SSR 125-12 125Vdc 200Vdc 12Adc 20Adc

*At 115V input on SSR 32-12 and SSR 63-12 and at 230V input on SSR125-12.

EXCITER MINIMUM FIELD DC RESISTANCE:

SSR Field Model Resistance

(Minimum)

SSR 32-12 2.5 ohms

SSR 63-12 5.0 ohm

SSR 125-12 10.0 ohms

POWER DISSIPATED: Less than 30 Watts

AC INPUT POWER: Designed for 50/60 Hz, self-excited, or 50-240 Hz separately-excited (PMG) applica-tions.

SSR Model Rated Voltage Burden

SSR 32-12 90 to 153 Vac, single phase, 50 to 240 Hz 700 VA

SSR 63-12 90 to 153 Vac, single phase, 50 to 240 Hz 1200 VA

SSR 125-12 170 to 305 Vac, single phase, 50 to 240 Hz 2400 VA

AC INPUT SENSING: Designed to regulate generator voltage at any frequency from 50 to 400 Hz

50 Hz Voltage 60/400 Hz Voltage

90-110 Vac 90-132 Vac

170-242 Vac 187-264 Vac

340-457 Vac 374-528 Vac

540-660 Vac

INPUT SENSING BURDEN: 3.5 VA per phase nominal.

PARALLELING COMPENSATION INPUT: 5A from Current Transformer with 10 VA maximum burden at 0.8 pf

REGULATION ACCURACY: ±0.25% from no-load to rated

THERMAL STABILITY: ±0.5% voltage variation for any 50o C (90oF) temperature change within operating tempera-ture range.

FREQUENCY COMPENSATION: Refer to Figures 1 and

2. Select from 50 or 60 Hz and a V/Hz or 2V/Hz curve in the field.

VOLTAGE BUILD-UP: From 5% of nominal.

TRANSIENT RESPONSE TIME: 1.5 cycles @ 60 Hz.

VOLTAGE ADJUST RANGE: External adjustment — ±10% of nominal. Internal adjustment minimum — see below:

Tap Minimum Adjustment Range

120 90-132 Vac

240 170-264 Vac

480 340-528 Vac

600 540-660 Vac

STORAGE TEMPERATURE RANGE: - 40o C (- 40oF) to +85oC (+185oF).

OPERATING TEMPERATURE RANGE: - 40o C (- 40oF) to +70oC (+158oF).

SHOCK: Withstands 15 Gs in each of three mutually perpendicular planes.

VIBRATION: Withstands the following:

Frequency Force

5- 26 Hz 1.2 G

27- 52 Hz 0.036 inch double amplitude

53-1000 Hz 5.0 G

WEIGHT: 12 lbs (5.5 kg) net 15 lbs. (7.0 kg) shipping

ACCESSORIES

The SSR series voltage regulators are designed to be compatible with any of the following Basler accessories and equipment:

a. Remote mounted Overexcitation Circuit Breaker. Part

Number 9185900014.

b. VAR/Power Factor Controller (SCP 250).

c. Current Boost System (CBS 212).

d. Current Transformers (CT2 through CT50).

e. Exciter Diode Monitor (EDM 200).

f. Minimum/Maximum Excitation Limiter (EL 200).

g. Auto-Synchronizer (BE1-25A).

h. Auto-Synchronizer (BE3-25A).

i. Line Drop Compensator (LDC 300).

j. Manual Voltage Control (Consult Factory).

k. Suppression Chassis P/N 9261500100 for SSR32-12 and 63-12 or P/N 9261500101 for SSR 125-12.

FIGURE 3 - TYPICAL INTERCONNECTION DIAGRAM

(Consult Instruction Manual for detailed interconnection instructions.)

FIGURE 4 - TYPICAL OVEREXCITATION CIRCUIT

BREAKER INTERCONNECTION

FIGURE 1 - 50 HZ FREQUENCY COMPENSATION FIGURE 2 - 60 HZ FREQUENCY COMPENSATION

ROUTE 143, BOX 269, HIGHLAND, ILLINOIS U.S.A. 62249

PHONE 618-654-2341 FAX 618-654-2351

P.A.E. Les Pins, 67319 Wasselonne Cedex FRANCE

PHONE (33-3-88) 87-1010 FAX (33-3-88) 87-0808

http://www.basler.com, info@basler.com

FIGURE 5 - TYPICAL OUTLINE DRAWING, SSR

FIGURE 6 - OPTIONAL CIRCUIT BREAKER

OUTLINE DRAWING

FIGURE 7 - DIMENSION DRAWING, Suppression Chassis 9261500100/101

Note: All dimensions are in inches (millimeters) All drawings and data subject to change without notice.

http://www.basler.com mailto:info@basler.com http://www.basler.com

FOR

STATIC VOLTAGE REGULATOR

Models: SSR 32-12NF

SSR 63-12NF

SSR 125-12NF

Part Numbers: 9 1859 00 106, 9 1859 00 108, and 9 1859 00 109

Publication Number: 9 1859 00 992 Revision: B 05/2001

SSR Introduction i

INTRODUCTION

This manual provides information concerning the operation and installation of Static Voltage Regulators.

To accomplish this, the following is provided.

• Specifications

• Functional Description

• Installation Information

• Operation

• Maintenance

WARNING

TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE, ONLY QUALIFIED

PERSONNEL SHOULD PERFORM THE PROCEDURES PRESENTED IN THIS

MANUAL.

CAUTION

Meggers and high potential test equipment should be used with extreme care.

Incorrect use of such equipment could damage components contained in the device.

ii SSR Introduction

First Printing: July 1991

Printed in USA

© 1999 - 2001, Basler Electric Co., Highland, IL 62249

May 2001

CONFIDENTIAL INFORMATION

OF BASLER ELECTRIC COMPANY, HIGHLAND, IL. IT IS LOANED FOR

CONFIDENTIAL USE, SUBJECT TO RETURN ON REQUEST, AND WITH THE

MUTUAL UNDERSTANDING THAT IT WILL NOT BE USED IN ANY MANNER

DETRIMENTAL TO THE INTEREST OF BASLER ELECTRIC COMPANY.

It is not the intention of this manual to cover all details and variations in equipment, nor does this manual provide data for every possible contingency regarding installation or operation. The availability and design of all features and options are subject to modification without notice. Should further information be required, contact Basler Electric Company, Highland, Illinois.

BASLER ELECTRIC

ROUTE 143, BOX 269

HIGHLAND, IL 62249 USA

http://www.basler.com, info@basler.com

PHONE 618-654-2341 FAX 618-654-2351

SSR Introduction iii

CONTENTS

SECTION 1 GENERAL INFORMATION......................................................................................................1-1

Description .................................................................................................................................1-1 Specifications.............................................................................................................................1-1 Accessories................................................................................................................................1-3 Spike Suppression Module .......................................................................................................1-3

SECTION 2 INSTALLATION ........................................................................................................................2-1

Mounting ....................................................................................................................................2-1 Voltage Regulator Mounting ...........................................................................................2-1 Spike Suppression Module Mounting.............................................................................2-2

Interconnection ..........................................................................................................................2-2 General ............................................................................................................................2-2 Regulator Sensing Connections .....................................................................................2-3 Field Power Connection ..................................................................................................2-7 Input Power......................................................................................................................2-7 External Control Input......................................................................................................2-7 Remote Voltage Adjust Rheostat....................................................................................2-7 Parallel Compensation ....................................................................................................2-8 Reactive Droop Compensation.......................................................................................2-8 Reactive Differential (Cross-Current) Compensation.....................................................2-8 Overexcitation Circuit Breaker ........................................................................................2-8

SECTION 3 OPERATION .............................................................................................................................3-1

Front Panel Controls and Indicators .........................................................................................3-1 VOLT Adjustment ............................................................................................................3-1 STAB Adjustment ............................................................................................................3-1 DROOP ADJUST Control ...............................................................................................3-1

Optional Voltage Shutdown Switch...........................................................................................3-1 Initial Operation..........................................................................................................................3-2

Preliminary Instructions...................................................................................................3-2 System Check-out ...........................................................................................................3-2

Field Flashing.............................................................................................................................3-2 Parallel Operation......................................................................................................................3-3

Preliminary Instructions...................................................................................................3-3 Preliminary Operation......................................................................................................3-3 Conditions Necessary for Paralleling..............................................................................3-3 Paralleling Operation.......................................................................................................3-3

SECTION 4 MAINTENANCE........................................................................................................................4-1

Preventive Maintenance............................................................................................................4-1 Corrective Maintenance ............................................................................................................4-1 Warranty and Repair Service....................................................................................................4-1 Troubleshooting.........................................................................................................................4-1 Operational Testing ...................................................................................................................4-1 iv SSR Introduction

CONTENTS-Continued

SECTION 5 REPLACEMENT PARTS .........................................................................................................5-1 General ......................................................................................................................................5-1

SECTION 6 MANUAL CHANGE INFORMATION ......................................................................................6-1

Changes ....................................................................................................................................6-1

SSR General Information 1-1

SECTION 1 • GENERAL INFORMATION

DESCRIPTION

The Basler SSR Series Voltage Regulators precisely controls the output voltage of an ac electric generating system by controlling the amount of current supplied to the exciter (or generator) field. The SSR Series Voltage Regulators are for use on brushless generators that require a high performance regulator and use a wide range of accessory devices.

Both the SSR 63-12NF and SSR 125-12NF have full-wave outputs, while the SSR 32-12NF is of the half-wave output type.

SPECIFICATIONS

Refer to Table 1-1 for the electrical specifications and to Table 1-2 for the physical specifications.

Table 1-1. Electrical Specifications

Input Power Requirements

SSR 32-12NF:

SSR 63-12NF:

SSR 125-12NF:

100 to 139 Vac ±10% (Nominal), 1 φ, 50 to 240 Hz., 700 VA 100 to 139 Vac ±10% (Nominal), 1 φ, 50 to 240 Hz., 1200 VA 190 to 277 Vac ±10% (Nominal), 1 φ, 50 to 240 Hz., 2400 VA

Input Sensing Requirements:

50 Hz:

60 Hz:

90-110/170-242/340-457 Vac, 3 φ (selectable 1 φ) 90-132/187-264/374-528/540-660 Vac, 3 φ (selectable 1 φ)

Input Sensing Burden: 10 VA per phase.

Paralleling Compensation Input: 5 A from CT at rated load with 10 VA maximum burden at 0.8 pf.

Regulation Accuracy: ±0.25% from no-load to full-rated load.

Thermal Stability: ±0.5% for any 50°C change within operating range.

Power Dissipated: 30 W maximum.

Power Output:

SSR 32-12NF:

SSR 62-12:NF

SSR 125-12NF:

32 Vdc/12 A Continuous; 50 Vdc/20 A Forcing (115 V input).

63 Vdc/12 A Continuous; 100 Vdc/20 A Forcing (115 V input).

125 Vdc/12 A Continuous; 200 Vdc/20 A Forcing (230 V input).

Minimum Field Resistance:

SSR 32-12NF:

SSR 63-12NF:

SSR 125-12NF:

2.5 ohms

5.0 ohms

10.0 ohms

Voltage Build-Up: From 6 volts residual or more (12 V for the SSR 125-12NF only).

Internal Voltage Adjust Range (Minimum):

For 120 V Tap: 90 to 132 Vac;

For 240 V Tap: 170 to 264 Vac;

For 480 V Tap: 340 to 528 Vac;

For 600 V Tap: 540 to 660 Vac.

External Voltage Adjust Range: ±10% of nominal.

Optional Circuit Breaker: Rated at 20 A, 277 Vac, 50/60 Hz., with a 5000 A interrupting capacity.

1-2 SSR General Information

Table 1-1. Electrical Specifications - Continued

Overexcitation Protection: Removes excitation if the regulator output is at 95% of rated forcing voltage for more than 60 seconds or instantaneously (<1 second) if output exceeds 130 % of rated forcing voltage. Refer to Figure 1-1.

Figure 1-1. Overexcitation Shutdown Curve

Table 1-2. Mechanical Specifications

Storage Temperature Range: -40°C (-40°F) to +85°C (+185°F).

Operating Temperature Range:

-40°C (-40°F) to +70°C (+158°F).

Humidity: The control module is totally protected for humidity and condensation by encapsulation.

Vibration: Withstands the following:

5 to 26 Hz. at 1.2 G's;

27 to 52 Hz. at 0.036 inch double amplitude;

53 to 1000 Hz. at 5.0 G's.

Shock: Withstands 15 G's in each of three mutually perpendicular planes.

Weight: 12 lbs. (5.5 kg) net; 15 lbs. (7.0 kg) shipping.

Overall Dimensions:

Height:

Width:

Depth:

9.0 inches (230 mm)

11.1 inches (281 mm)

3.6 inches (93 mm)

Optional Circuit Breaker:

Shock:

Vibration:

Weight:

Withstands 100 G's.

Withstands 10 G's.

10 ounces (280 grams) net.

SSR General Information 1-3

ACCESSORIES

The SSR Series Voltage Regulators are designed to be compatible with any of the Basler accessories and equipment listed below:

a. Remote mounted Overexcitation Circuit Breaker (P/N 9 1859 00 014). Refer to Section 2 for more information.

b. VAR/Power Factor Controller (SCP 250)

c. Series Boost Option (SBO 160)

d. Current Transformers (CT2 through CT50)

e. Exciter Diode Monitor (EDM 200)

f. Minimum/Maximum Excitation Limiter (EL 200)

g. Auto-Synchronizer (BE3-25A)

h. Auto-Synchronizer (BE1-25A)

i. Line Drop Compensator (LDC 300)

j. Low and Medium Power Isolation Transformers. Refer to Table 1-3.

Table 1-3. Transformer Selection

Voltage SSR 32-12NF SSR 63-12NF SSR 125-12NF

240/480 BE22207-001 BE22209-001 BE12819-001

600 BE22207-001 BE11050-001 BE22209-001

2400/4160 BE22208-001 BE13487-001 BE12818-001

7200 BE22210-001 BE22136-001 BE22136-001

13800 BE22210-001 BE21327-001 BE21327-001

* Transformers used with the SSR 32-12NF are designed to be compatible with the regulator's half-wave dc output.

SPIKE SUPPRESSION MODULE

Some higher impedance power sources (such as power isolation transformers and PMG's) may have enough inductance to cause potentially damaging voltage spikes in the power output stage of the SSR Voltage Regulator. In these cases, Basler Electric recommends the use of the Spike Suppression Module which was supplied with the Regulator to filter out these potentially damaging voltage spikes.

Refer to Section 2 for mounting and interconnection instructions.

SSR Installation 2-1

SECTION 2 • INSTALLATION

MOUNTING

Voltage Regulator Mounting

The Voltage Regulator will operate when mounted in any position, however, it should be vertically mounted to obtain optimum cooling. The Regulator can be mounted in any location where the ambient temperature does not exceed the operational limits. Due to its rugged construction, the Regulator can be mounted directly on the generator. Mounting hardware should be selected based upon the vibration and shock expected to be encountered during shipping/transport and normal operation. Refer to Figure 2-1 for the outline drawing of the unit which provides overall and mounting dimensions.

Figure 2-1. SSR Regulator, Outline Drawing

2-2 SSR Installation

Spike Suppression Module Mounting

The Spike Suppression Module will operate when mounted in any position. The Spike Suppression Module can be mounted in any location where the ambient temperature does not exceed the operational limits. Due to its rugged construction, the Spike Suppression Module can be mounted directly on the generator. Mounting hardware should be selected based upon the vibration and shock expected to be encountered during shipping/transport and normal operation. Refer to Figure 2-2 for the outline drawing of the unit which provides overall and mounting dimensions.

Figure 2-2. Spike Suppression Module, Outline Drawing

INTERCONNECTION

CAUTION

Meggers and high potential test equipment must not be used. Incorrect use of such equipment could damage the semiconductors in the Regulator.

General

The Regulator must be connected to the generator system as instructed in this section and as shown in the basic interconnection diagrams (refer to Figures 2-3 through 2-5).

NOTE

If the input power source is from a power isolation transformer or a PMG, the Spike Suppression Module should be connected to provide transient voltage spike protection for the Regulator.

SSR Installation 2-3

Regulator Sensing Connections

Three-Phase Sensing

The SSR Voltage Regulators contain internal sensing transformers with taps for the various input sensing voltages. Connect the input sensing (external terminals) as follows (refer to Figure 2-3):

(a) Connect terminal TB2-E1 (C) to phase A.

(b) Connect terminal TB2-E2 (Taps for 120, 240, 480, and 600 Vac are provided) to phase B.

CAUTION

Be sure to use the same value tap for TB2-E3 that was used for TB2-E2.

(c) Connect terminal TB2-E3 (Taps for 120, 240, 480, and 600 Vac are provided) to phase C.

(d) Be sure to remove any jumper installed across terminals TB1-21 and TB1-22.

Single-Phase Sensing

The SSR Voltage Regulators use the same internal sensing transformer for single-phase sensing that it uses for three-phase sensing. Connect the input sensing (external terminals) as follows (refer to Figure 2-4):

(a) Install a jumper between terminals TB1-21 and TB1-22.

(b) Connect terminal TB2-E1 (C) to phase A.

(c) Connect terminal TB2-E3 (Taps for 120, 240, 480, and 600 Vac are provided) to phase C.

2-4 SSR Installation

Figure 2-3. Typical SSR Voltage Regulator Interconnection, Single-Phase Sensing

SSR Installation 2-5

Figure 2-4. Typical SSR Voltage Regulator Interconnection, Three-Phase Sensing

2-6 SSR Installation

Figure 2-5. SSR Voltage Regulator Interconnection with PMG

SSR Installation 2-7

Field Power Connection

(1) Be sure to observe polarity and connect the field leads to terminals TB2-F+ and TB2-F-.

(2) The dc resistance of the field to which the Regulator is connected (terminals TB2-F+ and TB2-F-) must be equal to, or greater than that specified in Table 1-1. If the resistance is less than the specified minimum, a resistor must be added in series with the field. This resistor value plus the field resistance, must be equal to or greater than the minimum field resistance.

Input Power

(1) The input power connected to terminals TB2-3 and TB2-4 should be fused and may be taken from any generator lines that provide the correct voltage (line-to-line or line-to-neutral) as specified in Table 1-1. If line-to-neutral is used with a grounded neutral, it is strongly recommended that a power isolation transformer be used to limit the possibility of a ground loop. The phase relationship on this input to the other inputs is not important.

(2) When the generator output voltage does not match the values given in Table 1-1, a power transformer must be used to match the generator output to the Regulator input (refer to Table 1-3 for proper transformer selection).