Related Manuals for ABB AMG 0180
Summary of Contents for ABB AMG 0180
- Page 1 User’s Manual AMG Synchronous Generator Industrial Application Series Generator type: AMG 0180-AMG 0500 Serial number: Document number: 8AMG5854948 Revision: D (09/2011)
-
Page 2: Table Of Contents
CONTENTS Chapter 1 Introduction ................5 General information ................... 5 European directives .................. 5 Site conditions ................... 6 Important note ................... 6 Limitation of liability .................. 6 General safety .................... 7 1.6.1 Symbols and decals ................8 1.6.2 Electrical hazard ................... 8 1.6.3 Moving parts .................. - Page 3 3.1.2 Removal from storage ................ 19 3.1.3 Check of foundation ................19 3.1.4 Disassembly of the transport locking device ........20 3.1.5 Coupling type..................20 3.1.6 Assembly of the coupling half ............. 21 3.1.7 Belt drive .................... 21 Installation and alignment ..............21 3.2.1 Run-out of the coupling halves ............
- Page 4 Safety precautions................... 38 Maintenance program ................39 7.3.1 Recommended maintenance program ..........41 Maintenance of general construction ............ 43 7.4.1 Checks during running of the machine ..........43 7.4.2 Vibration and noise ................44 7.4.3 Temperature levels ................45 7.4.4 The tightness of fastenings ..............
- Page 5 9.1.4 Support for service centers ..............68 9.1.5 After sales contact information ............68 Spare parts ....................68 9.2.1 General spare part considerations............68 9.2.2 Periodic part replacement ..............69 9.2.3 Need of spare parts ................69 9.2.4 Selection of the most suitable spare part package ......69 9.2.5 Typical recommended spare parts in different sets ......
-
Page 6: Chapter 1 Introduction
ABB constantly strives to improve the quality of the information provided in this User’s Manual, and will welcome any improvement suggestions. For contact information, see Chapter 9.1. After sales. -
Page 7: Site Conditions
Figure 1- 1. CE-label. 1.3 Site conditions The machinery is to be used on a site with conditions according to Technical Specifications and Conditions laid down by ABB in their contract with the user, and nowhere else. 1.4 Important note The information in this document may sometimes be of a general nature and applicable to various machines supplied by ABB. -
Page 8: General Safety
ABB factory, which supplied the machine. NOTE: Local ABB sales offices or third party resellers may hold different warranty details, which are specified in the sales terms, conditions or warranty terms. -
Page 9: Symbols And Decals
Personnel must be familiar with the recommended procedures detailed in the User’s Manual. 1.6.1 Symbols and decals Personnel must be familiar with all the warning symbols and decals fitted to the machinery. Failure to recognize a warning and read the associated safety instructions may result in injury or death. -
Page 10: Transport, Storage
These machines are intended for industrial and commercial installations as components as defined in the Machinery Directive (MD) 98/37/EC. Commissioning is prohibited until conformity of the end product with this directive has been established (follow particular local safety and installation rules as e.g. -
Page 11: Operation
Chapter 7. Maintenance in the User’s Manual. Preserve these safety instructions! 1.8 Disposal and recycling instructions ABB is committed to its environmental policy. We strive continuously to make our products environmentally more sound by applying results obtained in recyclability and life cycle analyses. Products, manufacturing process as well as logistics have been designed taking into account the environmental aspects. -
Page 12: Recycling Of Material Required For Transport
1.8.1 Recycling of material required for transport After unpacking of the machine, the package has to be removed. The package is made of wood and can be burned. The plastic material around the machine can be recycled. After installation of the machine transportation locking have to be removed. The transportation locking is made of steel and can be recycled. - Page 13 Due to various installations used for the purpose it is not possible for ABB to give detailed instructions of the heat treatment process or the maintenance of the heat treatment equipment. These aspects must be taken care by the customer.
-
Page 14: Chapter 2 Transport And Storage
Chapter 2 Transport and storage 2.1 Transport and unpacking 2.1.1 Protective measures prior to transport The following protective measures are taken before delivery of the machine from the factory. The same protective measures should be taken, whenever the machine is moved: •... -
Page 15: Checks Upon Arrival And Unpacking
Figure 2-1. Lifting of unpacked machines. NOTE: • The machine must be lifted from its frame. Do not attempt to lift the machine from the top cover! • Do not lift the complete generating set by the generator lifting points. •... -
Page 16: Bearing Plate
Unpacking Place the synchronous machine so that it does not hinder the handling of any other goods and on a flat, vibration-free surface. When the package has been removed, a check should be made to see that the machine is not damaged and that all accessories are included. Tick off the accessories on the packing list which is enclosed. -
Page 17: Storage
2.2 Storage 2.2.1 Short term storage (less than 2 months) The machine should be stored in a proper warehouse with a controllable environment. A good warehouse or storage place has: • A stable temperature, preferably in the range from 10 V C (50 V F) to 50 V C (120 V F). -
Page 18: Very Long Term Storage (Over 6 Months)
Storage indoors To store the machine indoors: • If the machine is stored in its transportation package, make big enough holes on the sides of the transportation package so that the D-end and ND-end of the machine are accessible. • If the protection made by the manufacturer has been removed, protect the unpainted surfaces such as shaft extensions, coupling discs, coupling halves and jacking screws with suitable anti-corrosion agent. -
Page 19: Regular Checks During Storage
Table 2-1. Tightening torque for horizontal machines (lubricated screw). Axially locating Tightening Tightening bearing type torque/[Nm] torque/[lb ft] 6317 6319 6322 6324 6326 2.2.5 Regular checks during storage The following checks should be made regularly during storage. Every month: • Check that the anti-condensation heaters or alternative method of heating the machine is working. -
Page 20: Chapter 3 Installation And Alignment
(see Chapter 5. Commissioning). 3.1.3 Check of foundation The structural design of the foundation is not included in the ABB scope, and the customer or a third party is therefore responsible for this. Page 19... -
Page 21: Disassembly Of The Transport Locking Device
The installation of the machine should be planned as early as possible. Before lifting the machine onto the foundation: • Check that the position of the fixing holes and the height of the foundation are in agreement with corresponding measurements on outline and foundation drawings in Annex 1. -
Page 22: Assembly Of The Coupling Half
The machine is normally transported and lifted as one ready assembled unit onto the foundation, see Annex 1. Main Dimension Drawing. NOTE: The customer is responsible for machine installation (unless mentioned otherwise in the contract). ABB cannot be hold responsible for damage Page 21... -
Page 23: Run-Out Of The Coupling Halves
which may occur to the machine or to surrounding equipment subsequent to: • Excessive transmitted vibrations. • Poor design of foundations and/or structures. • Poor installation. • An alignment fault. • Poor storage conditions. • Non-respect of check instructions before start up. •... -
Page 24: Alignment Of Machines
Figure 3-2. Measuring the run-out at the coupling half. 3.2.2 Alignment of machines In order to ensure a long and satisfactory lifetime of both the driving and driven machine, the machines have to be properly aligned to each other. This means that the radial, as well as the angular deviation between the two shafts of the machine has to be minimized. - Page 25 NOTE: After aligning of the machine, tighten the screws coupling the flange and the flywheel housing first. Then tighten the screws for the coupling discs and the flywheel across. Alignment of the generator without coupling discs The alignment is done in accordance with the recommendations given by the coupling manufacturer.
- Page 26 Figure 3-5. Alignment check with gauges 2. Measure and note readings for parallel, angular and axial misalignment in four different positions: top, bottom, right and left, i.e. every 90°, while both shafts are turned simultaneously. Record the readings in the Annex 5. Commissioning Report. 3.
- Page 27 0,35 0,30 0,25 0,20 0,15 0,10 0,05 0,00 Temperature increase/[K] AMG 0180 AMG 0200 AMG 0250 AMG 0280 AMG 0315 AMG 0355 AMG 0400 AMG 0450 AMG 0500 Figure 3-6. The Correlation between thermal expansion and machine temperature rise.
-
Page 28: Final Inspection Of Installation
permissible misalignments shown in Table 3-1. Recommended permissible misalignments Table 3-1. Recommended permissible misalignments. Coupling information Permissible misalignment Coupling diameter Coupling type Rigid flange 0,02 mm 0,01 mm 0,02 mm (0,8 mil) (0,4 mil) (0,8 mil) 100-250 mm Gear 0,05 mm 0,03 mm 0,05 mm (4-10") -
Page 29: Chapter 4 Electrical Connections
Chapter 4 Electrical connections 4.1 General Electrical connections are made after the mechanical installation and alignment procedures. The electrical connections include the connection of main and auxiliary cables, earthing cables and possible external components. In order to determine proper actions, see Annex 3. Main Connection Drawing, Annex 4. Connection Instructions, Annex 10. -
Page 30: Mechanical Installation
emergency regulator in the event of failure of the voltage regulator. The limiter functions are not active in this mode. 4.2.3 Mechanical installation If the AVR is delivered as a separate item, the unit should only be installed in indoor areas which are dry and dust-free and do not contain any gases, acid fumes or similar. -
Page 31: Earth Connection
L1 L2 L3 L1 L2 L3 Figure 4-1. Phase sequence (IEC). In Figure 4-1.: • CW=clockwise. • CCW=counter clockwise (facing generator drive end). The neutral terminal is marked with the letter N. 4.3.3 Earth connection The ground cable can be connected inside of the main terminal box. 4.3.4 Insulation distances of main power connections The connections of the main power cables are designed to withstand demanding operation conditions where the insulators can be subjected to dirt, humidity and... -
Page 32: Chapter 5 Commissioning
NOTE: The commissioning report has to be sent to ABB in order to obtain future warranty claims. A recommended commissioning report can be found in Annex 5. Commissioning Report. -
Page 33: Insulation Resistance Measurements
Checking at site before first run All the settings has to be checked once more at the site of the generator. If there is need to change the settings it must be done by a qualified person such as an ABB or AVR representative. -
Page 34: Running The Machine The First Time
Recommended values for synchronizing are: • U=2 %. • f=0.7 %. • phase angle<15º. Maximum values U=4.5 % and f =4.0 % should not be exceeded. NOTE: Operation of the machine at reduced speed under 75 % of rated speed should be avoided. -
Page 35: Shut Down
If available, and after the machine has been running for several hours, measure the vibrations or SPM-values from the SPM-nipples, and record the values for future reference use. 5.8 Shut down The shut-down of the machine depends on the application, but main guidelines are: 1. -
Page 36: Chapter 6 Operation
NOTE: The machine may have hot surfaces when running with load. NOTE: Overloading the machine may cause winding damages. 6.2 Normal operating conditions The machines supplied by ABB are individually designed to operate in normal operating conditions according to the IEC standard, technical specifications and internal ABB standards. -
Page 37: Start-Up Procedure
Additional protection: • Frequency disturbance. • Reverse power. • Diode fault. • Vibration level. NOTE: Depending on the scope of the supplied generator, only some of the protections may be applicable in practice. Necessary level of generator protection shall be defined by the customer and necessary items shall be included in the generator scope on request. -
Page 38: Shut Down Procedures
6.6 Shut down procedures To stop the synchronous machine: 1. Switch the main breaker open. 2. Switch excitation off (if applicable). When the synchronous machine is not in operation, anti-condensation heaters must be switched on to avoid condensation inside the machine. For detailed shut down instructions, see Chapter 5.8. -
Page 39: Chapter 7 Maintenance
In case some of this data indicates something out of the ordinary, the trouble shooting guides in Chapter 8. Troubleshooting, will aid in locating the reason for the trouble. ABB recommends the use of experts in the creating maintenance programs, as well as in performing the actual maintenance and possible trouble shooting. -
Page 40: Maintenance Program
1.6. Safety Instructions. 7.3 Maintenance program This chapter presents a recommended maintenance program for ABB machines. This maintenance program is of a general nature, and should be considered as a minimum level of maintenance. Maintenance should be intensified when local conditions are demanding or very high reliability is required. - Page 41 beginning to develop before they cause failures and unscheduled maintenance breaks. It gives also suggestions what maintenance issues must be performed in the next larger overhaul. The maintenance can be estimated to last approximately 4-8 hours, depending on the type and installation of the machine and the depth of the inspections. Tools for this maintenance include normal servicing tools i.e.
-
Page 42: Recommended Maintenance Program
Tools for this maintenance include the same tools as for L3, and in addition, the rotor removal equipment. The preparations consist of opening the inspection covers, and the removal of rotor and exciter, if applicable. The amount of spare parts required for this level of maintenance is difficult to determine. - Page 43 Table 7-4. Maintenance objects for cable connection. Maintenance Check / Test object Cabling V/T/D Wear, fastening Connections V/T/D Oxidation, fastening Terminal box General condition Condition of cables Cable transits entering the machine and inside the machine Table 7-5. Maintenance objects for stator and rotor. Maintenance Check / Test object...
-
Page 44: Maintenance Of General Construction
Table 7-6. Maintenance objects for excitation system. Maintenance Check / Test object Exciter diode V/T/C V/T/C V/T/C Cleanliness, operation bridge Exciter V/T/C V/T/C V/T/C Operation, fixing semiconductors Exciter V/T/C V/T/C V/T/C Fixing, general condition connections Exciter winding Wear, cleanliness, insulation insulation resistance Exciter air gap V/T/D... -
Page 45: Vibration And Noise
7.4.2 Vibration and noise High or increasing vibration levels indicate changes in the machine's condition. Normal levels vary greatly depending on the application, type and foundation of the machine. The vibration measurements and levels are discussed in detail in Chapter 5. Commissioning. Some typical reasons that might cause high noise or vibration levels are: •... -
Page 46: Temperature Levels
transducers at any angular position on the bearing cap or frame. Vertical and horizontal directions are usually preferred for horizontally mounted machines. In some cases it may be recommended to measure the vibration also in the axial direction. When recording the results of the measurements, record the specific locations and directions with the actual values. -
Page 47: The Tightness Of Fastenings
7.4.4 The tightness of fastenings The tightness of all fastenings should be verified regularly. Special focus should be given to fixing and the rotor parts, which must remain correctly tightened at all times. Loose fastening in these parts can lead to sudden and severe damage to the entire machine. -
Page 48: Bearing Construction
The bearings must be removed by using pullers and fitted by heating, or using special tools for the purpose. NOTE: If there is a need to change bearings, please contact ABB After Sales, see After Sales contact information in Chapter 9.1.5. After Sales contact information. -
Page 49: Re-Greasing Intervals
Higher speed operation, e.g. in frequency converter applications, or lower speed with heavy load will require shorter lubrication intervals or a special lubricant. Consult manufacturing ABB factory After Sales department in such cases. NOTE: The constructional maximum speed of the machine must not be exceeded. -
Page 50: Bearing Plate
Automatic re-greasing A variety of automatic re-lubrication systems is available on the market. However, ABB recommends only the use of electromechanical re-lubrication systems. The quality of the grease entering the bearing has to be checked at least once per year: the grease has to look and feel like new grease. -
Page 51: Bearing Grease
NOTE: Lubricants containing EP admixtures are not recommended. NOTE: Different makes of grease must not be mixed, unless the compatibility has been verified. Recommended rolling bearing grease ABB recommends any of the following high performance greases to be used: • Esso Unirex N2 (lithium complex base). •... -
Page 52: Fitting And Replacing The Closed Nde Bearing
Figure 7-1. The bearing puller. 6. Check the O-ring seal and the preloading wavy washer and replace them (if necessary) Re-fitting the new bearing 1. Clean the shaft end. 2. Fit a new bearing, after heating it by induction system to 80 °C maximum. NOTE: Do not hit or press to the outer ring during assembly, as this will damage the balls. -
Page 53: Maintenance Of Stator And Rotor Winding
This chapter offers a general description on how to perform basic maintenance and tests. In many countries, ABB Service also offers complete service maintenance packages, which include comprehensive testing. Before conducting any maintenance work on the electrical windings, general electrical safety precautions are to be taken and local regulations are to be respected in order to prevent personnel accidents, see Chapter 7.2. -
Page 54: Timing Of The Maintenance
• Wear safety gear such as glasses, shoes, hard hat and gloves and suitable protective clothing to protect the skin. Protective creams should always be used. • Spray-varnish equipment, the frame of the machine, and the windings should be earthed during spray-varnishing. •... - Page 55 NOTE: Windings should be earthed briefly immediately after measurement in order to avoid risk of electric shock. Conversion of measured insulation resistance values In order to be able to compare measured insulation resistance values, the values are stated at 40 °C. The actual measured value is therefore converted to a corresponding 40 °C value with the help of the following diagram (see Figure 7-2.
- Page 56 NOTE: The insulation resistance indicated in the test report is normally considerably higher than the values measured on site. Minimum values for insulation resistance The following criteria apply to windings in a normal condition. Generally, the insulation resistance values for dry windings should exceed the minimum values significantly.
- Page 57 the windings. The frame and the two phases not measured are earthed, see part c of Figure 7-3. Connection of the stator windings for insulation resistance measurements. In the figure M represents the insulation resistance tester. NOTE: When phases are measured separately, all star-points of the winding system must be removed.
-
Page 58: Polarization Index
Figure 7-4. Connections for insulation resistance measurements. 1) Measurement of windings of the rotors. 2) Measurement of the stator winding of the excitation machine. M represents the insulation resistance meter. 7.6.5 Polarization index For the polarization index test the insulation resistance is measured after the voltage has been applied for 15 seconds and 1 minute (or 1 minute and 10 minutes). -
Page 59: Visual Winding Inspection
7.6.7 Visual winding inspection Winding inspections give information on: • The rate of contamination; presence of dirt and humidity. • Stability of bracings, vibration marks, and cracking. • Marks of overheating. • Marks of movement. • Tightness of the slot wedges. •... -
Page 60: Drying
If extraordinary circumstances occur and other maintenance is required, it is best to acquire professional help. The ABB After Sales organization is happy to assist in question regarding maintenance of electrical machine windings, for contact information see Chapter 9. -
Page 61: Maintenance Related To Electrical Performance, Excitation, Control And Protection
7.7 Maintenance related to electrical performance, excitation, control and protection The electrical performance of a synchronous machine is mostly defined by the condition of the rotor and stator windings and the operation of the excitation system. main machine winding maintenance described Chapter 7.6. -
Page 62: Maintenance Related To Thermal Performance And Cooling System
• Open the service doors at N-end shield of the machine. • Disconnect the wires connected to the diodes and exciter winding connection cables. • Check the condition of the diodes by measuring the resistance over a diode in both directions. •... - Page 63 When abnormal temperature rise has been detected, it should be also checked that temperature measurement system is operating correctly. Page 62...
-
Page 64: Chapter 8 Troubleshooting
The checks and corrective actions mentioned should always be conducted by qualified personnel. If in any doubt, the After Sales of ABB should be contacted for more information or technical assistance regarding troubleshooting and maintenance. -
Page 65: Mechanical Performance
8.1 Mechanical performance Table 8-1. Trouble shooting for mechanical performance. Troubleshooting Mechanical performance " " " & " " " Page 64... -
Page 66: Lubrication System And Rolling Bearings
8.2 Lubrication system and rolling bearings Table 8-2. Trouble shooting for lubrication and rolling bearings. Page 65... -
Page 67: Thermal Performance, Open Air Cooling System
8.3 Thermal performance, open air cooling system Table 8-3. Troubleshooting for thermal performance. Troubleshooting Thermal performance, open air cooling system & & " " " " , " " " " Page 66... -
Page 68: Electrical Performance And Excitation System Of Generators
8.4 Electrical performance and excitation system of generators Table 8-3. Trouble shooting for electrical performance. Troubleshooting Electrical performance and excitation system of generators with transformer excitation , " " " " " " " " & " " " & &... -
Page 69: Chapter 9 After Sales And Spare Parts
Chapter 9 After sales and spare parts 9.1 After sales The after sales support for rotating electrical machines manufactured by ABB. 9.1.1 Site services The Service department provides: • Installation and commissioning • Maintenance and inspections • Trouble shooting and service •... -
Page 70: Periodic Part Replacement
9.2.4 Selection of the most suitable spare part package ABB provides three levels of ready made spare part packages. The personnel best informed of the machine's operational conditions should select the most suitable package based on criticality of the application and on the financial risk related to the duration of downtime and loss of production. -
Page 71: Order Information
Please note that even though ABB has customized the spare part sets to match the machine, they might contain references to accessories not found on all machines. 9.2.5.1 Operational spare parts package Spare part: Amount: Automatic voltage regulator (AVR) 1 pc...