Electro Adda G Series Manuel utilisateur

MM-12-rev 01-EN

ASYNCHRONOUS THREE-PHASE GENERATORS

G LINE

OPERATING INSTRUCTIONS

MM-13- rev 01-EN

GENERAL SAFETY WARNINGS...........................................................................................................................3

DESCRIPTION OF THE GENERATORS ...............................................................................................................4

GENERAL INFORMATION................................................................................................................................4

G-C LINE .............................................................................................................................................................4

G-W LINE ............................................................................................................................................................4

G-QN AND G-A LINE ...........................................................................................................................................5

GENERAL FEATURES...........................................................................................................................................7

REFERENCE STANDARDS..............................................................................................................................7

MANUFACTURING DETAILS............................................................................................................................8

Frame and stator............................................................................................................................................8

Stator winding and insulation.........................................................................................................................9

Rotor ..............................................................................................................................................................9

Non-drive end shield......................................................................................................................................9

Drive end shield/Flange.................................................................................................................................9

The drive end shield or flange is made in cast iron or steel and is fixed to the frame using high tensile

strength screws..............................................................................................................................................9

Bearings.........................................................................................................................................................9

Appropriate covers are also provided to prevent leakage of lubricant from the bearings.............................9

Line terminal box..........................................................................................................................................10

DOCUMENTATION..........................................................................................................................................13

IDENTIFICATION OF THE GENERATOR.......................................................................................................13

RECEIPT...............................................................................................................................................................14

GENERATOR HANDLING.......................................................................................................................................14

STORAGE.............................................................................................................................................................14

INSTALLATION AND COMMISSIONING ............................................................................................................15

Assembly and disassembly of the transmission component.......................................................................15

Alignment.....................................................................................................................................................16

Vertical deviation..........................................................................................................................................18

Axial displacement.......................................................................................................................................18

Electric connections.....................................................................................................................................20

OPERATION .........................................................................................................................................................22

OPERATING CONDITIONS.....................................................................................................................................22

SAFETY NOTICE..................................................................................................................................................22

CHECKS DURING OPERATION...............................................................................................................................22

Vibration check ............................................................................................................................................23

MAINTENANCE....................................................................................................................................................24

PREVENTIVE MAINTENANCE .......................................................................................................................24

GENERAL CLEANING.....................................................................................................................................25

Cleaning the windings..................................................................................................................................25

Drying the windings......................................................................................................................................25

MAINTENANCE OF THE BEARINGS..............................................................................................................26

Features of the grease.................................................................................................................................26

Changing the grease....................................................................................................................................27

Cleaning the bearings..................................................................................................................................27

Disassembly of the bearings........................................................................................................................27

Mounting the bearings .................................................................................................................................27

SPARE PARTS.....................................................................................................................................................28

Ordering spare parts....................................................................................................................................28

Storage of spare parts .................................................................................................................................28

MEASUREMENT OF INSULATION RESISTANCE.............................................................................................29

MM-13- rev 01-EN

GENERAL SAFETY WARNINGS

Installation, operating and maintenance of electric generators can be potentially dangerous. All

precautions and measures must therefore be taken to prevent the occurrence of such dangerous

situations.

NOTICE

Electric generators are components with dangerous parts as they are live or have parts which

move while in operation. Therefore:

incorrect use,

removal of protections without isolating the power supply,

disconnection of protection devices,

failure to perform inspections or maintenance,

may cause serious injuries to people.

In particular, maintenance interventions must be carried out exclusively by qualified staff i.e. persons

with specific knowledge, experience, appropriate professional training, knowledge of safety

regulations, standards, accident prevention provisions and working conditions. Safety managers

must authorise this staff to perform the necessary jobs and prevent any danger (also refer to IEC 364

Standard for the definition of qualified staff).

For jobs in plants with high electric currents, the access and work prohibition for unqualified staff is

ruled by the IEC 364 Standard as well.

This manual contains some of the symbols used to warn about any danger which could arise during

the various operations.

The symbols, together with relative wording “Danger”, “Caution” and “Warning” indicate the potential

risk from not complying with the prescriptions which they are coupled up with.

The following table gives the meaning of the symbols:

DANGER - RISK OF ELECTRIC SHOCK

Warning that there is a risk of electric shock if this notice is ignored

DANGER

Warning that there is a risk of serious injury if this notice is ignored

CAUTION

Warning that there is a risk of damage to persons and/or objects if this notice is

ignored

WARNING

Warning that there is a risk of damage to the generator or to the driving unit if

this notice is ignored

For reasons of general clarity, this manual does not contain all cases of operation, maintenance and

possible repairs. Therefore it mainly contains only the information required by qualified personnel

(see above) if the machines are used, as intended, as traction motors. In case of problems,

especially for more detailed information, we recommend you to always clearly indicate the machine

type and serial number.

MM-13- rev 01-EN

DESCRIPTION OF THE GENERATORS

GENERAL INFORMATION

The G Line asynchronous three-phase generators frame size 280÷560 described in this operating

and maintenance manual are designed in order to consider the different requirements in the field of

low voltage generation, in the range of outputs included within 150 and 2000 kW.

The series of basic machines is made up of different executions both as protection degree and

cooling type as described hereunder:

G-C Line

The G-C Line generators are of the enclosed type provided with fins, with external ventilation

(IC411) and IP54 protection degree.

This constructive solution allows to make a generator that can be installed also outdoors without any

additional protection.

G-W Line

The G-W Line generators are made with IC7A1W7 cooling system made up by a primary cooling fluid

(air) with a heat exchanger built-in in the generator frame that uses fresh water coming from a remote

circuit.

MM-13- rev 01-EN

The water cooling is a very efficient system to remove the heat produced by the generator. This

system allows to significantly reduce the dimensions and the weight of the generator.

The water cooling also allows to:

Reduce the heat transmitted to the room

Reduce the noise transmitted

Reduce the vibrations transmitted to the foundation

Avoid to raise dust in the room

Reduce the dimensions of the machines

G-QN and G-A Line

The G-A Line is made up by a self-ventilated generator with IP23S protection degree.

The cooling air, by means of a fan fixed directly on the generator shaft, is normally sucked on the top

and is ejected by proper grids placed on the bottom in correspondence of the coupling flange.

The G-A Line is suitable to be installed indoors.

MM-13- rev 01-EN

All G Line generators are designed, manufactured, assembled and tested at our works in

BEVERATE di BRIVIO - Lecco - ITALY.

MM-13- rev 01-EN

GENERAL FEATURES

REFERENCE STANDARDS

The G Line generators are in compliance with the following Standards:

RATINGS AND PERFORMANCES IEC 60034-1 CEI EN 60034 – 1

METHODS FOR DETERMINING LOSSES AND EFFICIENCY IEC 60034 - 2 CEI EN 60034–2

CLASSIFICATION OF DEGREES OF PROTECTION (IP CODE) IEC 60034-5 CEI EN 60034–5

METHODS OF COOLING (IC CODE) IEC 60034 - 6 CEI EN 60034–6

CLASSIFICATION OF TYPE OF CONSTRUCTION AND MOUNTING ARRANGEMENTS (IM

CODE) IEC 60034-7 CEI EN 60034–7

TERMINAL MARKINGS AND DIRECTION OF ROTATION IEC 60034-8 CEI 2-8

BUILT-IN THERMAL PROTECTIONS IEC 60034-11

MECHANICAL VIBRATIONS IEC 60034-14 CEI EN 60034–14

DIMENSIONS AND POWERS OF ELECTRIC MACHINES IEC 60072-1

MM-13- rev 01-EN

MANUFACTURING DETAILS

The G Line generators described in this manual have been designed and are manufactured in order

to assure the maximum operating reliability and safety.

G-C Line generators - Materials

Frame size

160 180 200 225 250 280 315 355 400 450 500 560

Frame Aluminium Steel

DE shield Cast iron Steel

NDE shield Cast iron Steel

Flange Cast iron Steel

Shaft Steel C40 ( on request 39NiCRMd4 )

Terminal box Aluminium Steel

G-W Line generators - Materials

Frame size

160 180 200 225 250 280 315 355 400 450 500 560

Frame Steel

DE shield Cast iron Steel

NDE shield Cast iron Steel

Flange Cast iron Steel

Shaft Steel C40 ( on request 39NiCRMd4 )

Terminal box Aluminium Steel

G-QN – G-A Line generators - Materials

Frame size

160 180 200 225 250 280 315 355 400 450 500 560

Frame Steel

DE shield Cast iron Steel

NDE shield Cast iron Steel

Flange Cast iron Steel

Shaft Steel C40 ( on request 39NiCRMd4 )

Terminal box Aluminium Steel

Frame and stator

The frame is the external envelope of the generator and, besides the structural function, it also

conveys the cooling fluid and the cooling air.

In the W Line generators it also acts as a heat exchanger.

The stator core complete with the windings is placed inside the frame.

The stator lamination core consists of thin thickness (0,65 mm.) magnetic laminations. Longitudinal

grooves, called slots, are made in the part of the laminations nearest to the air gap, distributed evenly

around the air gap with the winding housed inside them.

The stator slots are half-open to make it easier to insert the winding wires.

The laminations used are insulated, the ones from the others, to reduce losses from eddy currents.

The laminations of the generator core are made of low loss steel sheet alloyed with silicon, to reduce

iron losses and consequently improve the general performance of the generator.

In W Line generators, the cooling circuit of the generator itself is obtained inside the frame.

MM-13- rev 01-EN

Stator winding and insulation

Materials used to make the windings and the insulation system are in class H.

Stator winding is three-phase AC with coils manufactured with enamelled copper wire and positioned

in bulk in the stator slots.

The copper wire used for stator winding is insulated using enamel made with modified polyesterimide

resins plus amide-imide resins, with 200°C heat class.

Stator slots are insulated using "NOMEX” sheets

Finally, the winding is exposed to a vacuum impregnation process in autoclave using hot polimerizing

resins to guarantee further insulation and tightly gathering the bundles of copper, which are subject to

electro-dynamic stress.

Rotor

The rotor of the generator is made of a laminated core obtained with the same lamination types of

the stator core.

C Line generators up to frame size 315 and W and Q Line generators up to frame size 280, are

normally provided with rotor made with aluminium die cast cage. This solution provides an excellent

stiffness of the rotor core.

Generators in bigger frame sizes are provided with squirrel cage rotor made in copper with

rectangular section.

The bars of the cage are connected to each other by means of copper rings. These rings are welded

to the bars using a welding process in an atmosphere of inert gas.

The realization of the rotor cage made as indicated above allows to reduce the rotor losses (thanks to

reduced resistivity) and to obtain a higher efficiency and lower general heating of the machine.

Non-drive end shield

The non-drive end shield is made in cast iron or steel and is fixed to the frame using high tensile

strength screws.

In generators with vertical axis, the NDE end shield houses the thrust bearing suitable to bear the

load arising from the rotor weight or for special executions the turbine weight.

Drive end shield/Flange

The drive end shield or flange is made in cast iron or steel and is fixed to the frame using high tensile

strength screws.

Bearings

The generator is provided with grease-lubricated rolling bearings.

The shield supports have a Tecalemit-type greasing nipple to allow re-lubrication of the bearing and a

plug for the drainage of the consumed grease.

Appropriate covers are also provided to prevent leakage of lubricant from the bearings.

In generators with vertical axis, the upper bearing is able to bear the weight arising from the rotor

weight and of a normal shaft coupling.

On request the generator can be provided with upper bearing able to bear also loads arising from the

weight of the turbine impeller and from the hydraulic load.

MM-13- rev 01-EN

Line terminal box

The terminal block for generators frame size 250÷355 is normally provided with 6x terminals; the

terminal block for generators frame size 400÷560 is provided with 3 terminals only (one each phase),

to which the supply cables are connected.

In such case the connection of the windings is made inside the machine itself and it is not accessible.

On request, also generators frame size 400÷560 can be made with 6 terminals in order to have all

winding terminals accessible.

The terminal block is made in anti-mould non-hygroscopic material.

As mentioned, the terminal box (in aluminum alloy for the generators frame size 250÷355 and in steel

plate for bigger frame sizes) has IP 55 or IP 56 protection degree, provided that the connection of the

supply cables is properly made.

Dimensions of terminal box and block for generators frame size 250 ÷ 355

TIPO PRESSACAVO

Type A B C D E F Cable Gland

160 - 180 188 86 82 52 M8 30 M40x1.5

200LT 188 86 95 60 M8 35 M40x1.5

200 - 225 225 103 95 60 M10 35 M50x1.5

250MT 225 103 115 70 M10 45 M50x1.5

280ST-MT 276 120 125 80 M12 45 M50x1.5

315 375 145 145 90 M14 54 N.2 M63x1.5

355 L - Lx 430 165 165 100 M16 65 N.2 M63x1.5

Dimensions of terminal box and block for generators frame size 400 ÷ 560

Generators frame size 400÷560 are provided with steel terminal box and, as mentioned, they can be

provided with 3 or 6 terminals. Terminal boxes are supplied with a removable plate for the cable exit

to be drilled by the customer.

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