Mecc Alte ECO47 Series Installation, Use And Maintenance Manual

Self-regulating alternators
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Self-regulatig alteriators
ECO47-49 MV-HV
Iistallatoi, Use aid Maiiteiaice Maiual
Translatin if the iriginal instructins
Dicument cide: MAOMAPPA022-GB
Revisiin: 0
Date: 03/17/2020

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Summary of Contents for Mecc Alte ECO47 Series

  • Page 1 Self-regulatig alteriators ECO47-49 MV-HV Iistallatoi, Use aid Maiiteiaice Maiual Translatin if the iriginal instructins Dicument cide: MAOMAPPA022-GB Revisiin: 0 Date: 03/17/2020...
  • Page 3: Table Of Contents

    Table of contents Geieral Iiformatoi..........................9 Respinsibility if the user......................9 Warranty............................9 After-sales assistance.........................10 1.3.1 Infirmatin required ti ibtain after-sales assistance..........10 Addressees if the manual......................10 Machine identicatin details....................11 1.5.1 Descriptin if the priduct cide.................12 CE certicate..........................13 Manufacturer’s identicatin details..................13 Structure if dicumentatin.......................13 1.8.1 Cimpisitin if the dicumentatin................13 1.8.2...
  • Page 4 Transpirt............................29 4.1.1 Packaging........................29 4.1.2 Lifting and handling.....................30 4.1.3 Stirage........................32 4.1.4 Measuring the insulatin resistance................32 Checking the supply........................32 Characteristcs if the installatin site..................32 Installatin..........................33 4.4.1 Directin if ritatin if the alternatir................33 4.4.2 Ciupling the alternatir aith the prime engine............34 Ciupling aith jiint - Dual suppirt alternatirs................34 Ciupling via SAE fange- Single suppirt alternatirs..............35 Cimpensatin fir thermal dilatin....................36 Vertcal thermal dilatin......................36...
  • Page 5 Exciter statir ainding.........................67 Exciter ritir ainding........................68 PMG ainding..........................68 6.3.1 Cinversiin if the values relatve ti the insulatin resistance........69 Nites............................69 Maintenance if the suppirts.....................70 6.4.1 Lubricatng the bearings....................70 6.4.2 Replacing grease in the bearings.................71 Alternatirs ECO47 (see 6.6.1 Disassembly of the Alternators ECO47)........71 Alternatirs ECO49 (see 6.6.2 Disassembly of the Alternators ECO49)........71 6.4.3 Replacing the bearings....................72...
  • Page 6 Disassembly..........................119 9.2.1 Disassembly if the machine..................119 Stirage.............................120 9.3.1 Shirt-term stirage....................120 9.3.2 Electric and electrinic cimpinents................121 9.3.3 Ling term stirage.....................121 Stirage fir mire than 18 minths....................121 Dispisal............................122 9.4.1 Dispisal if the machine....................122 Eiclosed documeitatoi.......................123 10.1 Diagrams and draaings......................123 10.1.1 List if diagrams and draaings...................123 10.2 Cimpinents dicumentatin....................123 10.2.1 List if cimpinent dicumentatin................123...
  • Page 7 List of figures Figure 1- Data plate example.....................11 Figure 2- Alternatirs ECO47......................21 Figure 3- Alternatirs ECO49......................21 Figure 4- ECO47 - 1 bearing.......................28 Figure 5- ECO47 - 2 bearings.....................28 Figure 6- ECO49 - 1 bearing.......................28 Figure 7- ECO49 - 2 bearings.....................28 Figure 8- Transpirt in pallet.....................30 Figure 9- Transpirt in pallet civered aith crate...............31 Figure 10- Directin if ritatin if the alternatirs..............33...
  • Page 8 List of Tables Table 1 - Generatir plate data....................11 Table 2 - Descriptin if the priduct cide.................12 Table 3 - Winding cide......................12 Table 4 - Alignment - Individual suppirt..................23 Table 5 - Alignment - Dual suppirt....................23 Table 6 - Niise...........................24 Table 7 - Vilume if air required....................24 Table 8 - Deratng cieefcient.....................24 Table 9 - Resistance if the aindings at riim temperature 20 °C - Alternatirs ECO47.....26...
  • Page 9: Geieral Iiformatoi

    Mecc Alte S.p.a. Warraity The filliaing cinditins invalidate the terms if Warranty privided by Mecc Alte S.p.a.: ● Inappripriate use, ir in ither airds, the use if the machine ither than as described in Piint 2.1 Intended Use.
  • Page 10: After-Sales Assistance

    ● Inspectins and repair iperatins 1.3.1 Iiformatoi required to obtaii after-sales assistaice Whenever Mecc Alte S.p.a. after-sales assistance is required, the filliaing data must be privided regarding the Self-regulatng alternatirs (see alsi 1.5 Machine identicaton details): ● Type and midel if the alternatir.
  • Page 11: Machine Identicatin Details

    Machiie ideiticatoi details These instructins refer ti the filliaing Self-regulatng alternatirs midels: Name: Self-regulatng alternatirs Midels: ECO47-49 MV-HV An identicatin plate listng its main characteristcs has been applied ti the machine. See alsi 1.5.1 Descripton of the product code. Figure 1- Data plate example Phases Number if phases I [A]...
  • Page 12: Descriptin If The Priduct Cide

    1.5.1 Descriptoi of the product code Every alternatir is identied by a unique cide made up as described belia. Cide example: ECO47HV-1L/4A T60H5S6 Descriptin: Type if alternatir ECO47 ECO47 ECO49 Viltage range HV: > 7.2 kV MV: >= 1 kV LV: <...
  • Page 13: Ce Certicate

    Revisiin Date 03/17/2020 ● The set if enclised dicuments listed in 10.1 Diagrams and drawings and 10.2 Components documentaton. Cintact Mecc Alte S.p.a. if in diubt regarding the structure and use if such dicumentatin. Self-regulating alternators ECO47-49 MV-HV Page 13/124...
  • Page 14: Cintent If The Manual

    1.8.2 Coiteit of the maiual This manual and its enclised dicumentatin enclised privide infirmatin in the filliaing aspects. General infirmatin and safety infirmatin are cintained in the filliaing chapters: 1 General Infirmatin 2 Safety Descriptin if the machine and the iperatin if its cimpisite parts, transpirt and installatin methids, and methids if use: 3 Descriptin and features 4 Transpirt and installatin...
  • Page 15: Symbils And Cinventins Used In This Manual

    Symbols aid coiveitois used ii this maiual Several cinventins are used in this manual ti privide the necessary infirmatin. The cinventins used are explained belia. 1.9.1 Deiiitoi of wariiig levels Nitces cintaining aarnings and explanatins are used ti aarn users if pitental dangers ir draa atentin ti partcularly dangerius ir risky iperatins.
  • Page 16: Cinventins Used In The Text

    Notce Nitces if this type identfy a situatin if pitental danger, ahich if nit aviided, ciuld priduce damage ti priperty. NOTICE Cause if danger Pissible cinsequences ● Actin required ti aviid the danger Note NOTE This notce provides useful informaton regarding the safe and efcacious use of the machine. 1.9.2 Coiveitois used ii the text Texts preceded by ine if the filliaing symbils: ➔...
  • Page 17: Safety

    ● If in diubt ir yiu have priblems understanding this manual ir any if its parts, ae recimmend cintactng Mecc Alte S.p.a. ● Cintact Mecc Alte S.p.a. exclusively fir any type if technical assistance required. Self-regulating alternators ECO47-49 MV-HV Page 17/124...
  • Page 18: Users And Their Riles

    After-sales Service techiiciai The Mecc Alte S.p.a. After-sales Service Technician is an appripriately trained and authirised persin ahi respinds directly ti Mecc Alte S.p.a. and is capable if perfirming maintenance and repair iperatins in the machine. Self-regulating alternators ECO47-49 MV-HV...
  • Page 19: Safety Rules

    ● Whenever diubts arise in regard ti iperatin, di nit intervene directly but cintact the manufacturer Mecc Alte S.p.a. ● In additin ti the priduct dicumentatin enclised aith the machine, alsi respect the standards and regulatins in firce giverning accident preventin and safety in the airkplace.
  • Page 20: Residual Risks

    Residual risks The Self-regulatng alternatirs have been manufactured in cimpliance aith current safety criteria. In spite if this, residual risks linked ti their iperatin remain that may cause injury ti persinnel ir damage ti priperty in partcular cases. DANGER Miving mechanical parts. Risk if crushing, dragging ir entrapment.
  • Page 21: Descriptoi Aid Features

    3 Descriptoi aid features Descriptoi of the Self-regulatig alteriators ECO47-49 MV-HV Figure 3- Alternators ECO49 Figure 2- Alternators ECO47 1- Terminal bixes 2- Aux. bix 3- PMG (permanent magnet alternatir) 4- Alternatir ciiling air inlet 5- NDE shield 6- Casing 7- Cables passage aperture in nin-magnetc material.
  • Page 22: Der2 Viltage Regulatir

    The shaft is in C45 steel aith lick-set fan. The pritectin ratng is IP23. Isilatins are perfirmed in class H aith impregnatin in epixy resin and vacuum-treated high- viltage parts, such as the statirs (special treatments are available in request). 3.1.1 DER2 voltage regulator The DER2 is a viltage regulatir fir synchrinius alternatirs, set-up fir iperatin and calibratin in stand-aline mide.
  • Page 23: Technical Features

    Techiical features Belia ind the technical features if the Self-regulatng alternatirs. Refer alsi ti the alternatir Test Repirt, see 10 Enclosed documentaton. 3.3.1 Alteriator electric data Refer ti the data plate ixed ti the machine (see Figure 1- ) 3.3.2 Aligimeit with the motor Alignment tilerances if the alternatir aith the prime engine.
  • Page 24: Niise In Db (A)

    3.3.3 Noise ii dB (A) Alteriator 50 Hz 60 Hz ECO47 ECO49 Table 6 - Noise 3.3.4 Volume of air required (m /mii) Alteriator 50 Hz 60 Hz ECO47 4A ECO49 4A Table 7 - Volume of air required 3.3.5 Iistallatoi alttude The perfirmance if the alternatir is afected by the installatin alttude and the temperature.
  • Page 25: Resistance If The Aindings

    3.3.6 Resistaice of the wiidiigs ECO47 Type Voltages Pitch Alteriator Exciter PHASE- Ritir [Ω] 50Hz / 60Hz Statir [Ω] PHASE- PHASE statir ±5% [Ω] ±5% ±5% PHASE ritir [mΩ] ±5% [mΩ] ±5% ECO47MV 1M4 A 19,3 1,23 1.5 / 1.3 12.9 ECO47MV 2M4 A 15,8...
  • Page 26: Table 9 - Resistance If The Aindings At Riim Temperature 20 °C - Alternatirs Eco47

    Type Voltages Pitch Alteriator Exciter PHASE- Ritir [Ω] 50Hz / 60Hz Statir [Ω] PHASE- PHASE statir ±5% [Ω] ±5% ±5% PHASE ritir [mΩ] ±5% [mΩ] ±5% ECO47HV 2M4 A 10/10.5/11 274,1 1,34 1.5 / 1.3 12.9 ECO47HV 1L4 A 10/10.5/11 242,2 1,46 1.5 / 1.3...
  • Page 27: Table 10 - Resistance If The Aindings At Riim Temperature 20°C - Alternatirs Eco49

    Type Voltages Pitch Alteriator Exciter PHASE- Ritir [Ω] 50Hz / 60Hz Statir [Ω] PHASE- PHASE statir ±5% [Ω] ±5% ±5% PHASE ritir [mΩ] ±5% [mΩ] ±5% ECO49MV VL4 A 27,8 1.83 1.34 / 1.12 11.4 95.0 ECO49MV XL4 A 39,1 1.98 1.34 / 1.12 11.4...
  • Page 28: Clearance And Aeights

    3.3.7 Clearaice aid weights Figure 4- ECO47 - 1 bearing Figure 5- ECO47 - 2 bearings Figure 6- ECO49 - 1 bearing Figure 7- ECO49 - 2 bearings ECO47 ECO49 Weight Weight 2,374 1,634 1,140 6,400 2,355 1,704 1,280 9,100 2,174 1,634 1,140...
  • Page 29: Traisport Aid Iistallatoi

    4 Traisport aid iistallatoi Traisport Barring ither agreements betaeen Mecc Alte S.p.a. and the custimer, the transpirt if the cimpinents necessary fir the machine and all ither cimplementary equipment required fir iperatin is the respinsibility if Mecc Alte S.p.a. Transpirt must be perfirmed using suitable means and in cimpliance aith the regulatins in firce.
  • Page 30: Lifting And Handling

    4.1.2 Liftiig aid haidliig Respoisibility: Operator at the liftiig devices Prerequisites: The followiig must be available: ● Suitable lifting equipment such as a crane, hiist, lifting truck ir trans-pallet. ● Cables, chains, clevis, eyebilts as required DANGER Beaare if suspended liads. Risk if death due ti crushing by falling liads filliaing release ir breakage if lifting ripes ir hiiks.
  • Page 31: Figure 9- Transpirt In Pallet Civered Aith Crate

    Figure 9- Transport on pallet covered with crate NOTE Lifting devices such as ropes or straps can damage the alternators terminal board box if the ixing angle is too acute. Make sure that the lifting devices do not touch the terminal board box during operatons. NOTICE Once ciupled, the alternatir cannit be lifted aith the prime mitir.
  • Page 32: Stirage

    Mecc Alte S.p.a. aill nit accept any subsequent claims in regard. Characteristcs of the iistallatoi site The Self-regulatng alternatirs ECO47-49 MV-HV must be installed in an envirinment that has the filliaing features: ●...
  • Page 33: Directin If Ritatin If The Alternatir

    Iistallatoi Respoisibility: Service techiiciai Prerequisites: All compoieits iecessary are available aid ready for iistallatoin the equipmeit iecessary for iistallatoi ● Make sure that the base inti ahich the alternatir is ixed is stable and able ti suppirt the aeight. ● Befire installatin, check that the data indicated in the alternatir plate are suitable fir the features if the mains electricity if the service envisiined.
  • Page 34: Ciupling The Alternatir Aith The Prime Engine

    4.4.2 Coupliig the alteriator with the prime eigiie The Mecc Alte Piaer Priducts ritirs and alternatirs cimply aith the ISO 1940-1 Standard. Any excessive vibratins are ti be blamed therefire in the drive engine ir incirrect mitir-alternatir ciupling and ciuld lead ti damage ir breakage if the bearings.
  • Page 35: Ciupling Via Sae Fange- Single Suppirt Alternatirs

    Coupliig via SAE faige- Siigle support alteriators This ciupling must be perfirmed by the custimer and must be made in cimpliance aith the safety regulatins in firce via an appripriately dimensiined jiint. Alsi cimply aith the filliaing. ● The alternatir aith single suppirt requires a silid fat base in a aay ti perfirm cirrect alignment.
  • Page 36: Cimpensatin Fir Thermal Dilatin

    Compeisatoi for thermal dilatoi Regarding alignment if the cild machine, the alternatir and the engine can have diferent thermal dilatin cieefcients, ahich ahen hit can cause diferent dimensiinal changes betaeen these parts. The iperatng temperatures have a signiicant efect in the alignment tilerances and must be taken inti cinsideratin.
  • Page 37: Fixing The Alternatir Ti The Base

    Figure 14- L Quota 4.4.3 Fixiig the alteriator to the base CAUTION Inaccurate ixing cause iperatng priblems. Pissibility if damage ti the alternatir ir the prime engine due ti vibratins and mivement if the alternatir. ● Make sure that the alternatir is cirrectly ixed ti the surface.
  • Page 38: Electric Cinnectin

    4.4.4 Electric coiiectoi DANGER Presence if dangerius electric viltage. Risk if death filliaing electric shicks caused by cintact aith uncivered electric cables ir live parts. ● Remive the viltage befire priceeding aith the jib. ● Alaays use suitable Individual pritectin Equipment. DANGER Presence if viltage generated by the mivement if the alternatir engine.
  • Page 39: Terminals Bix Cinnectin

    Termiials box coiiectoi Cinnect the alternatir ti the utlity, making reference ti Figure 15- and Figure 16- . Figure 15- ECO47 terminals box Figure 16- ECO49 terminals box Self-regulating alternators ECO47-49 MV-HV Page 39/124...
  • Page 40: Figure 17- Phases Cinnectin Terminal

    Aux. bix Valve centre cinnectin Current sensir (TA) Viltage sensir (TV) Cables passage ipening Phases cinnectin terminals (U-V-W frim left ti right in Figure 15- and Figure 16- ) Ant-explisiin diaphragm Earth cinnectin Brass threaded bar M12 x 110 10- Cinnectin ti the viltage sensir 11- Vetrinite suppirt 12- Piaer terminal Figure 17- Phases connecton terminal...
  • Page 41: Auxiliaries Bix Cinnectin

    Auxiliaries box coiiectoi Make the cinnectins in the auxiliaries bix in cimpliance aith the Auxiliaries box wiring diagram, see 10.1 Diagrams and drawings. Figure 18- Generators auxiliaries box ECO47 and ECO49 Figure 19- DER 2 voltage regulator 1- DER2 viltage regulatir 2- Terminal biard 3- Cables passage hile ti the terminals bix 4- USB cinnectin...
  • Page 42: Setng The Alarm And Stip Temperature

    4.4.5 Setig the alarm aid stop temperature The pribes miunted in the alternatir detect the temperature if the ainding phases and the bearings (see alsi 3.1 Descripton of the Self-regulatng alternators ECO47-49 MV-HV). Refer ti the filliaing tables fir the cirrect temperature setng values. Isolatoi class of the Maximum coitiuous Alarm temperature °C...
  • Page 43: Alternatir Cinnectin Ti Earth

    4.4.6 Alteriator coiiectoi to earth Cinnect the alternatir ti earth in the piints indicated. The earth plate ti ahich the alternatir is cinnected must be cimpliant ti that envisiined by the laas in firce. Figure 20- Alternators ECO47 Figure 21- Alternators ECO49 Self-regulating alternators ECO47-49 MV-HV Page 43/124...
  • Page 44: Checks After Installatin

    Checks after iistallatoi Respoisibility: Service techiiciai Prerequisites: Iistallatoi of the alteriator is coicluded ➔ Perfirm cimmissiining at lia speed ➔ Check fir the presence if abnirmal niise ir vibratins that may indicate mechanical ciupling priblems NOTICE Pissible damage ti the shafts ir bearing due ti misalignment. ●...
  • Page 45: Der2 Digital Viltage Regulatir

    4.5.1 DER2 digital voltage regulator Refer alsi ti the DER2 viltage regulatir user manual, see 10.2 Components documentaton. In statc cinditins, the DER2 viltage regulatir guarantees viltage value accuracy if ± 1% aith any piaer factir and aith a speed change betaeen -5% and 20%. The regulatir can be cinnected ti a PC via a USB cinnectin accessible in the auxiliaries bix (see Figure 18- Generators auxiliaries box ECO47 and ECO49).
  • Page 46: Inputs And Iutputs Technical Data

    Iiputs aid outputs techiical data CONNECTOR CN1 Speciicatoi Termiial* Name Fuictoi Notes Exc- Cintnuius reg. 4 A dc Energisatin maximum Aux/Exc+ Transient reg.: 12 A dc peak 40 ÷ 270 Vac, Aux/Exc+ Piaer supply Frequency: 12 ÷ 72 Hz ** Scale 2: Sensing scale 2 150÷300 Vac...
  • Page 47 CONNECTOR CN3 Termiial Name Fuictoi Speciicatois Notes Cimmin Type: nin-isilated ipen cillectir iutput Prigrammable bith the Current: 100 mA Actve pritectins alarm that actvates it and iutput Viltage: 30 V A.P.O. the delay tme Maximum length: 30 m Cimmin Type: nin-isilated input Lia speed pritectin Bridge 50/60 Hz threshild selectin **...
  • Page 48: Figure 22- Withiut Saturatin If The Iutput Viltage

    The regulatirs miunted in the alternatirs are calibrated during the inal inspectin. In the case if regulatirs supplied separately (e.g. spare parts) ir ahenever cabling ir calibratin variatins are requested, the regulatir must be calibrated accurately. The main setngs can be carried iut directly in the regulatir via 4 trimmers (VOLT - STAB - Hz - AMP), the jumper 50/60, JP1, JP2 and the Pext input.
  • Page 49 50/60 sigial A jumper pisitined at the input 50/60 (cinnectir CN1 clamps 12 and 13) sets the saitch-iver if the lia speed pritectin threshild frim 50·(100%-αHz%) ti 60·(100%-αHz%), ahere αHz% represents the relatve pisitin if the trimmer Hz. APO coitact Acrinym if Actve Pritectin Output: (cinnectir CN1 terminals 14 and 15) in-isilated transistir ipen cillectir 30V-100 mA, nirmally clised by default.
  • Page 50 ➔ Ritate the Trimmer HZ cimpletely ant-clickaise. If the machine must iperate at 60 Hz: ✗ ➔ Make sure that the bridge is intriduced betaeen terminals 25 and 26 ➔ Take the alternatir ti a speed equal ti 96% if niminal speed ➔...
  • Page 51: Calibratin If The Stability If The Der 2 Viltage Regulatir

    It is impirtant ti highlight the Mecc Alte Piaer Priducts alternatirs are tested using an electric mitir nit a thermal mitir. Therefire, the STAB adjustment is set cirrectly fir the alternatir driven by electric mitir.
  • Page 52: Checking The Alternatir Iutput Viltage

    4.5.3 Checkiig the alteriator output voltage Respoisibility: Service techiiciai Prerequisites: The alteriator has beei correctly iistalled aid is at a staidstll Refer ti the auxiliaries airing diagram, see 10.1.1 List of diagrams and drawings. ➔ Check the viltage rati if the viltage sensir in the terminal bix accirding ti that stated in the plate aefxed ti the sensir;...
  • Page 53: Ciupling Tirques

    4.5.4 Coupliig torques Respect the ciupling tirques listed fir the screas indicated. Alteriator Thread Material Coupliig torque ECO47 B3B14 [Nm] ±7% Balancing template in ritir Cinvex cylindrical head aith hexagin sicket M8x20 Pritectin net IP23 Hex head M5x25 DE Bearing civer Hex head M6x100 DE Shield in statir Hex Head M16x60...
  • Page 54: Table 16 - Alternatirs Ciupling Tirque Eco47 Md35

    Alteriator Thread Material Coupliig torque [Nm] ECO47 MD35 ±7% Flexible discs Hex head M16x40 Balancing template in ritir Cinvex cylindrical head aith hexagin sicket M8x20 Pritectin net IP23 Hex head M5x25 DE Shield in statir Hex head M14x70 NDE Shield in statir Hex head M14x70 NDE Bearing lid Hex head M6x85...
  • Page 55: Table 17 - Alternatirs Ciupling Tirque Eco49 B3B14

    Alteriator Thread Material Coupliig torque ECO49 B3B14 [Nm] ±7% Fan in hub Hexagin sicket head cap screa M16x60 Balancing template in ritir Cinvex cylindrical head aith hexagin sicket M12x35 Exciter key in ritir shaft Hex head M8x40 Diides pirt template in exciter NUT M8 cl.8 Diides bridge in template...
  • Page 56: Table 18 - Alternatirs Ciupling Tirque Eco49 Md35

    Alteriator Thread Material Coupliig torque ECO49 MD35 [Nm] ±7% Flexible discs Hex head M20x60 Fan in hub Hexagin sicket head cap screa M16x60 Balancing template in ritir Cinvex cylindrical head aith hexagin sicket M12x35 Exciter key in ritir shaft Hex head M8x40 Diides pirt template in exciter NUT M8 cl.8...
  • Page 57: Operatoi

    5 Operatoi Commissioiiig of the alteriator Respoisibility: Machiie operator Prerequisites: The iistallatoi has beei completed correctly aid the alteriator is ready to fuictoi NOTE The cooling air intake and discharge apertures must always be free. For the volumes of cooling air necessary, see 3.3.4 Volume of air required (m3/min).
  • Page 58: Stipping The Alternatir

    Stoppiig the alteriator The alternatir is stipped aling aith the engine ti ahich it is cinnected. CAUTION Pissibility if firmatin if cindensate inside the alternatir. ● Make sure that the ant-cindensatin heaters remain in during the periid if inactvity if the alternatir. Open master saitch if the utlites cinnected befire stipping the prime mitir.
  • Page 59: Maiiteiaice

    6 Maiiteiaice The maintenance iperatins that the user can perfirm are described in this chapter. Other iperatins mentined but, aithiut descriptin if executin, are the respinsibility if the Mecc Alte S.p.a. after-sales service. Any iperatin in electrical parts, even nit live, must be perfirmed by specialised persinnel aith knialedge if the regulatins and safety standards regarding airk in electric cimpinents.
  • Page 60 ● Fir the maintenance interventins nit described in this manual, request the interventin if the machine manufacturer. ● Whenever signs if decreased perfirmance are nited, primptly cintact Mecc Alte S.p.a. Service. NOTICE Risk if damage ti the machine caused by the use if nin-iriginal spare parts.
  • Page 61: Maintenance Intervals

    Maiiteiaice iitervals These intervals must be respected in irder ti keep the machine in the safe and eefcient airking irder required fir cimplete aarranty civerage. All maintenance iperatins must be perfirmed by a persin (type if user) trained in the tasks required as indicated in 2.3 Responsibility of the user.
  • Page 62: Maintenance If The Statir And Ritir Aindings

    Maiiteiaice of the stator aid rotor wiidiigs The duratin if the electric machine is afected by the duratin if the aindings insulatin. The insulatin ages because it is subjected ti electrical, mechanical and heat phenimena. This pricess can be sliaed dian aith appripriate maintenance interventins. 6.2.1 Check coiditois of the wiidiigs Respoisibility: Service techiiciai or machiie operator Frequeicy: Every 2,500 hours...
  • Page 63: With Bateries Ir A Direct Current Piaer Supply Unit (24 V, 5 A)

    With bateries or a direct curreit power supply uiit (24 V, 5 A) CAUTION Damage ti the viltage regulatir if there is ni cinnectin betaeen regulatir and exciter. ● Remive the cinnectin betaeen PMG (permanent magnets alternatir that piaers the viltage regulatir) and the viltage regulatir.
  • Page 64: Cleaning The Aindings

    Frequeicy: Every 20,000 hours or more frequeitly ii the case of dusty eiviroimeits NOTE Contact Mecc Alte S.p.a. for thorough washing in case of windings in a very bad state. ➔ Disassemble the alternatir (see 6.6 Disassembly of the alternators) ➔...
  • Page 65: Measuring The Insulatin Resistance

    Measuriig the iisulatoi resistaice Respoisibility: Service techiiciai Prerequisites: Respect the followiig coiditois: ● The alternatir must be at a standstll ● The filliaing must be discinnected: ● Viltage transfirmers and current transfirmers ● Valve centre ● Piaer cables. Alsi see 6.6 Disassembly of the alternators. Frequeicy: Oice a year or if the machiie is at a staidstll for more thai two weeks Reference regulatin: IEEE STD 43-2000 DANGER...
  • Page 66: Main Statir

    Maii stator The insulatin resistance measurement betaeen the aindings and earth must be made aith the relevant measuring device, piaered aith direct current and iutput viltage as near as pissible ti the machine's niminal viltage. Priceed as fillias ti measure the insulatin resistance. ➔...
  • Page 67: Ritir Ainding

    Rotor wiidiig The insulatin resistance measurement betaeen the ainding and earth must be made aith the relevant measuring device, piaered aith direct current and iutput viltage if 500 V. The insulatin resistance must be measured betaeen the pisitve terminal ir the negatve terminal if the ritir ainding in the rectier bridge and the earth if the ritir.
  • Page 68 Exciter rotor wiidiig ➔ Measure the insulatin resistance betaeen phase and earth using an insulatin tester (megger) ✔ The minimum isilatin value must be 5 MΩ ✗ If the resistance is liaer than 5 MΩ ➔ Clean the ritir and impregnate it, if necessary ➔...
  • Page 69: Table 20 - Temperatures And Cirrectve Cieefcients

    ● Insulatin resistance values that are tii lia can indicate the presence if humidity ir dirt in the ainding, cintact Mecc Alte S.p.a. ti schedule the interventin if a technician. ● The insulatin resistance decreases aith the increase in temperature.
  • Page 70: Table 22 - Intervals If Suppirts Lubricatin And Type If Grease

    Maiiteiaice of the supports 6.4.1 Lubricatig the beariigs Respoisibility: Service techiiciai Prerequisites: The alteriator is at a staidstll CAUTION Lubricant grease can pillute the envirinment. Pissibility if pillutin if the land due ti the dispersiin if grease. ● Alaays dispise if grease accirding ti the regulatins in firce ir take it ti a cimpany specialised in the dispisal if special aaste.
  • Page 71 6.4.2 Replaciig grease ii the beariigs Respoisibility: Service techiiciai Prerequisites: The alteriator is at a staidstll Replacing the grease in the bearings invilves the remival if ild grease and tipping up aith nea grease. Priceed as indicated belia. The numbers indicated refer ti the disassembly and assembly iperatins if the alternatirs if chapters 6.6 Disassembly of the alternators and 6.7 Assembling of the alternators.
  • Page 72 6.4.3 Replaciig the beariigs Respoisibility: Service techiiciai or Mecc Alte S.p.a. After-sales service techiiciai Prerequisites: The alteriator is at a staidstll aid uicoupled from the prime eigiie Replace the bearings as indicated belia. The numbers indicated refer ti the disassembly and assembly iperatins if the alternatirs if chapters 6.6 Disassembly of the alternators and 6.7...
  • Page 73 6.5.3 Visual iispectoi Respoisibility: Service techiiciai or machiie operator Frequeicy: Every 2,500 hours Prerequisites: The alteriator is at a staidstll aid has cooled dowi ➔ Check fir the presence if dents, rust ir ither visible animalies; ➔ Check the cinditins if the piaer cinnectin cables and the regulatir cables; ➔...
  • Page 74: Figure 28- Ritatng Rectier

    6.5.5 Checkiig aid replaciig the diodes bridge Respoisibility: Service techiiciai Frequeicy: Ii the case of a fault Prerequisites: The alteriator is at a staidstll aid has cooled dowi The diides bridge is made up frim 3 blicks aith 2 diides (see la Figure 27- Rectier bridge). ➔...
  • Page 75 ● Check the integrity if the fuse inside the regulatir (see 6.5.8 Replacing the DER 2 voltage regulator fuse). If the priblems detected are nit silved, cintact the Mecc Alte S.p.a. after-sales service. Replace the regulatir if necessary. Self-regulating alternators ECO47-49 MV-HV...
  • Page 76 Prerequisites: The alteriator is at a staidstll aid discoiiected from the electric power supply NOTE The DER 2 voltage regulator must be set by Mecc Alte S.p.a. before assembly. The calibraton data must be communicated when a new regulator is ordered.
  • Page 77 6.5.9 Removiig the disc holder hub Respoisibility: Service techiiciai or machiie operator Prerequisites: The alteriator has beei uicoupled from the prime eigiie CAUTION Risk if hub falling. Pissibility if injury ti iperatir ir damage ti the hub. ● Suppirt the hub aith suitable lifting equipment during the inal extractin phase.
  • Page 78 Heatig aid extractoi Pisitin a three arm extractir and atach it ti the additinal fange; Heat the hub unifirmly using tai tirches; Pressurise the extractir untl the hub is remived cimpletely frim the shaft; ECO49 alteriators Remive the pritectin net in the SAE shield; Suppirt the ritir using a threaded bar M16 in the hub if the fan thriugh the hile FC;...
  • Page 79 There are tai diferent methids fir extractng the hub. Iitroduciig pressurised oil Use a sift belt, as a liip, ti fasten the hub ti be remived, in a aay ti prevent it falling ince extracted; Pump iil inti the hile (FO) indicated, untl iil starts ti escape frim the cintact area betaeen shaft and hub;...
  • Page 80 Disassembly of the alteriators The alternatir must be remived fir sime maintenance iperatins. Belia ind the descriptins if the disassembly iperatins ti ahich reference must be made inside the manual. 6.6.1 Disassembly of the Alteriators ECO47 Disassemble the alternatirs as described successively. The descriptin if the iperatins is distnguished by single suppirt alternatir midels (MD35) and dual suppirt midels (B3B14) and the cimmin iperatins fir the tai alternatir midels are indicated.
  • Page 81 13- Use eyebilts ti fasten the DE shield (13) cinnected ti the ritir ti suitable lifting equipment (aeight apprix. 2500 kg). 14- Liisen and remive the M16 screas (14). 15- Using the eyebilts in the DE shield (13), rest the ritir delicately in the statir. 16- Extract the DE shield (13).
  • Page 82 Removiig the SAE 18 discs - Siigle support alteriators. 21- Liisen and remive the M20x60 screas (8). 22- Remive the jiint press disc (9). 23- Remive the ciupling discs (10) and the spacer ring (E). 24- Use eyebilts ti fasten the DE shield (12) ti suitable lifting equipment (aeight apprix.
  • Page 83 29- Liisen the M5 TEIC screas (20) and remive the pritectin cap (21). 30- Insert a paper spacer (22) aith thickness if 0.2-0.3 mm betaeen statir and PMG ritir. 31- Liisen the central te-rid M14 (23) and, aithiut remiving it cimpletely, use it as a lever in the PMG in irder ti unciuple it frim the shaft.
  • Page 84 35- Liisen and remive the M8 nut (26). 36- Unscrea and remive the M8 (27) Hexagin sicket ciuntersunk fat head cap screas and the varistir suppirt bushing (28). 37- Liisen the M5 screas if the rectiers, remive the rectier piles cinnectin bridge (29) and the varistir (30).
  • Page 85 44- Remive the NDE shield (33) frim the bearing ahile maintaining it lifted via eyebilts (aeight apprix. 150 kg). NOTE If necessary, use an extractor to push between shaft and shield. 45- Extract the bearing (C): ● Use an extractir aith 3 arms. ●...
  • Page 86 48- Suppirt the ritir (43) in bith sides and extract it frim the machine. 49- As siin as pissible, suppirt the ritir by passing sift belts ariund the ritir pack and paying atentin nit ti apply firce ti the fan (42). NOTE Aitenton not to rub the rotor on the stator.
  • Page 87 6.6.2 Disassembly of the Alteriators ECO49 Disassemble the alternatirs as described successively. The descriptin if the iperatins is distnguished by single suppirt alternatir midels (MD35) and dual suppirt midels (B3B14) and the cimmin iperatins fir bith alternatir midels are indicated. Both alteriator models Remive the lid (1) if the terminal bix.
  • Page 88 12- Use sift belts ti fasten the DE shield (5) ti suitable lifting equipment. 13- Liisen the 12 x M20 x 65 hex head screas (8) and extract the shield (aeight apprix. 340 kg). Dual support alteriators Liisen the M12x110 hex head clamping screas and remive the bearing lid (E) in the ciupling side shield.
  • Page 89 10- Extract the bearing (C): ● Use an extractir aith 3 arms. ● Pull in the internal lid (P) instead if directly in the bearing. Both alteriator models 11- Remive the greaser pipe. 12- Remive the 12 x M6x30 hex head screas. 13- Remive the rear guard .(9) (aeight apprix.
  • Page 90 16- Liisen the central te-rid M14 (11) aithiut remiving it cimpletely. 17- Use the te-rid ti lever in the PMG device ti unciuple it frim the shaft. 18- Use a sift belt ti atach the PMG ti suitable lifting equipment. 19- Remive the 6 x M8 x 20 screas.
  • Page 91 25- Use M12 seas in the threaded hiles ti mive the NDE shield apprix. 10 mm frim the statir. 26- Keep the DE ritir lifted. 27- Place the ritir in the statir. NOTE Remove the DE shield only if it is necessary to extract the rotor from the machine.
  • Page 92 35- Extract the bearing (C): ● Use an extractir aith 3 arms. ● Pull in the internal lid (P) instead if directly in the bearing. Both alteriator models 36- The exciter statir (16) aill remain atached ti the NDE shield. 37- Unscrea the 6 x M12 x 90 hex head screas ti remive the shield.
  • Page 93 Assembliig of the alteriators 6.7.1 Assembliig Alteriators ECO47 Re-miunt the alternatirs as described successively. The descriptin if the iperatins is distnguished by single suppirt alternatir midels (MD35) and dual suppirt midels (B3B14) and the cimmin iperatins fir bith alternatir midels are indicated. NOTE Do not apply force onto the fan(2 )during operatons.
  • Page 94 10- Use eyebilts ti keep the NDE shield lifted (8) (aeight apprix. 150 kg). 11- Re-miunt the shield, by insertng the bearing inti the seat cimpletely. 12- Insert the grease threshild ring (9). 13- Insert the slinger ring (10). 14- Insert the bearing external lid (11) and ix it ti the internal lid using M12x100 hex head screas (12).
  • Page 95 17- Fix the unit (15) aith the M8x50 screas (16). 18- Cinnect the exciter ritir cables ti the 3 rectiers (C). 19- Cinnect the pisitve pile [+] if the ritir ainder ti the base if the unit (D). 20- Fix the cipper cinnectin clamp (17) using the rectier screas (A).
  • Page 96 24- Fix the PMG ritir (25) ti the shaft, via the central te-rid M14 (26). 25- Remive the paper spacer (27) present in the PMG gap. 26- Miunt the PMG pritectin cap (28) and ix it aith the M5x12 (29) lateral screas. 27- Pass all the piaer and auxiliary cables thriugh the hiles in the statir casing (30).
  • Page 97 Assembly of the shield - Dual support alteriators 31- Insert the bearing internal lid (34). 32- Fill the hillia (P) present in the bearing lid aith grease. 33- Pre-heat the bearing (35) ti 110 °C and intriduce it. 34- Prepare an M12 te-rid in ine if the threaded hiles if the bearing lid (36) ti facilitate alignment aith the external lid.
  • Page 98 Assembly of the shield - Dual Siigle support alteriators. 44- Use eyebilts ti fasten the DE shield (34) ti suitable lifting equipment (aeight apprix. 160 kg). 45- Place the DE shield at the statir casing and ix it using the M16x55 screas (35). Assembly of the SAE 21 discs - Siigle support alteriators.
  • Page 99 52- Fix the cables pritectin guard (43) ti the casing aith the M6x16 screas (44). 53- Miunt the base plate (45) if the terminal biard bix and ix it using theM12x35 screas (46). 54- Fix the cillar ti the base plate aith the M6x20 screas.
  • Page 100 Miunt the exciter statir (2) in the NDE shield (1) using the 6 x M12 x 90 hex head screas. Miunt the bearing suppirt aith the 6 x M12 x 40 hex head screas. Self-regulating alternators ECO47-49 MV-HV Page 100/124...
  • Page 101 Fill the hillia present in the internal lid (P) if the bearing aith grease. Insert the cimpinents indicated in this irder: ● the internal lid if the bearing (P). ● the bearing (C) appripriately pre-heated ti 110 °C. Prepare an M12 te-rid in ine if the threaded hiles ti facilitate the successive alignment if the external lid.
  • Page 102 16- Miunt the rectier bridge: ● Fix the unit (2) aith the 3 x M8 x 40 screas. M8 x 40 ● Cinnect the three cables if the exciter ritir frim the bridges (C), aling aith the cinnectin (+) if the ritir ainding (D). ●...
  • Page 103 19- Remive the paper spacer (6) present in the PMG gap. 20- Miunt the pritectin cap (7) if the PMG and ix it aith the 2 x M5 x 10 cinvex hex sicket head screas. 21- Pass all piaer and auxiliary cinnectins thriugh the upper aindia if the shield NDE.
  • Page 104 Siigle support alteriators 25- Lift the DE shield (aeight apprix. 340 kg) using a suitable lifting device. 26- Ciuple the statir case and ix it using the 12 x M20 x 65 screas. 27- Miunt the ciupling discs SAE (9), ixing them aith the 24 x M20 x 60 screas.
  • Page 105 34- Use sift belts ti lift the DE shield (A) (aeight apprix. 340 kg). 35- Miunt the shield si that the bearing enters the seat. 36- During insertin, pay atentin ti the directin if the internal lid, using the previiusly-inserted te- rid.
  • Page 106 47- Cinnect the piaer cables. 48- Miunt the auxiliaries cables straps. 49- Miunt the lateral panels (12) if the terminal bix and auxiliaries bix (10). 50- Cinnect the set-ups fir the vibratin sensirs ti the terminal bix (13). 51- Insert the auxiliaries bix and the terminals and cinnect them ti the terminal biard accirding ti the airing diagram.
  • Page 107 Belia ind a series if malfunctining symptims if the alternatir and pissible causes. If the indicatins privided di nit silve the priblem, cintact the Mecc Alte S.p.a. after-sales service. The references present in this manual ahich are useful fir silving the priblem are shian in this table in brackets.
  • Page 108 Problems of a mechaiical iature Symptom Probable cause Possible cause The alternatir vibrates and is niisy a- Incirrect ixing ti the base Check the ixing screas and Excessive netairk unbalance tghten if necessary Check that the netairk balance meets requirements Priblems aith lubricatin Check that the lubricant ●...
  • Page 109 8 Spare parts List of recommeided spare parts Belia ind the list if recimmended spare parts fir the alternatirs. Cintact the Mecc Alte S.p.a. After-sales service, if necessary. Refer alsi ti the assembly draaing if the alternatir, see 10.1 Diagrams and drawings.
  • Page 110 ECO47 B3B14 Self-regulating alternators ECO47-49 MV-HV Page 110/124...
  • Page 111: Table 23 - Spare Parts Eco47 B3B14

    Table 23 - Spare parts ECO47 B3B14 POS. Name Code FRONT GREASE SLINGER RING ECO47A 6801011208 FRONT GREASE THRESHOLD RING ECO47A 9810018014 BALL BEARING 6232 C3 9810027048 FRONT BEARING INTERNAL CLOSURE RING ECO47A 6801011209 FAN ECO47A WORKED 6801005030 MAIN ROTOR B3B14 EXCITER ROTOR ECO47A 6102521188 REAR BEARING INTERNAL CLOSURE RING ECO47A...
  • Page 112 ECO47 MD35 Self-regulating alternators ECO47-49 MV-HV Page 112/124...
  • Page 113: Table 24 - Spare Parts Eco47 Md35

    Table 24 - Spare parts ECO47 MD35 POS. Name Code JOINT PRESSING DISC MD35 SAE DISCS UNIT SAE JOINT HUB FAN ECO47A WORKED 6801005030 MAIN ROTOR MD35 EXCITER ROTOR ECO47A 6102521188 REAR BEARING INTERNAL CLOSURE RING ECO47A 6801011212 BALL BEARING 6226 C3 9810027049 REAR GREASE THRESHOLD RING ECO47A 9810018015...
  • Page 114 ECO49 B3B14 Self-regulating alternators ECO47-49 MV-HV Page 114/124...
  • Page 115: Table 25 - Spare Parts Eco49 B3B14

    Table 25 - Spare parts ECO49 B3B14 POS. Name Code NDE iiler ring MAPPA4534 Grease threshild ring MAPPA4535 DE Radial bearing (SKF6236-C3) 9810027010 DE Rear civer MAPPA4536 Fan ECO49 MAPPA4543 Cinnected ritir and shaft Cinnected exciter ritir H=70 mm MAPPA2374 NDE Rear civer MAPPA4539 NDE Radial bearing (SKF6236-C3)
  • Page 116 ECO49 MD35 Self-regulating alternators ECO47-49 MV-HV Page 116/124...
  • Page 117: Table 26 - Spare Parts Eco49 Md35

    Table 26 - Spare parts ECO49 MD35 POS. Name Code SAE discs press template MAPPA2392 Flyaheel discs 21 MAPPA2298 Hub jiint ECO49 MD35 MAPPA4669 Fan ECO49 MAPPA4543 Cinnected ritir and shaft Cinnected exciter ritir H=70 mm MAPPA2374 NDE Rear civer MAPPA4539 NDE radial bearing (SKF6236 M C3) 9810027010...
  • Page 118 Decommissioiiig aid removal 9.1.1 Stoppiig machiie operatoi Respoisibility: Service techiiciai or Mecc Alte S.p.a. After-sales service techiiciai Prerequisites: The machiie is at a staidstll aid isolated electrically from the maiis ➔ Isilate the machine frim the electric piaer supply siurces;...
  • Page 119 Disassembly 9.2.1 Disassembly of the machiie Respoisibility: Service techiiciai or Mecc Alte S.p.a. After-sales service techiiciai Prerequisites: The machiie is at a staidstll aid isolated electrically from the maiis Refer alsi ti 6.6 Disassembly of the alternators. CAUTION Lubricant liquids and ither pricess fuids harmful fir the envirinment are cintained in the machine and its piping.
  • Page 120 Storage NOTICE Pissible damage ti the alternatir is the insulatin resistance if the aindings dies nit lie aithin the values envisiined. Pissible cinsequences ● Check the value if the insulatin resistance befire cimmissiining. 9.3.1 Short-term storage Shirt-term stirage means a periid nit exceeding three minths. The filliaing measures must be cimplied aith during this periid.
  • Page 121 9.3.2 Electric aid electroiic compoieits It is preferable ti pisitin the electric and electrinic cimpinents in a place aith the filliaing features: ● cinstant temperature in the range if 10°C - 40°C ● relatve air humidity belia 75% ● giid ventlatin ●...
  • Page 122 Disposal 9.4.1 Disposal of the machiie Respoisibility: Operator/user Prerequisites: The procedure described ii 9.2.1 Disassembly of the machine has beei coicluded CAUTION Lubricant liquids, pricess fuids ir machine cimpinents are harmful fir the envirinment. Pissibility if pillutin if the surriunding envirinment aith tixic substances ir materials.
  • Page 123 10 Eiclosed documeitatoi This chapter lists the cimpinent dicuments and dicumentatin enclised ti this manual. See alsi 1.8 Structure of documentaton. 10.1 Diagrams aid drawiigs The filliaing diagrams and draaings are enclised aith this manual. 10.1.1 List of diagrams aid drawiigs Documeit ttle Documeit code File...

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