Cosimat
Cosimat
Cosimat
6. Technical data
GENERAL DATA Type : fully potted aluminium housing incl. power stage
Maintenance : maintenance-free
Rated switch-on time : continuous operation
Installation position : mount with longitudinal axis vertical at
convectional cooling or longitudinal axis
in air flow direction at fan cooling
Installation clearance : 3 cm all round
(see 11.2 Mounting the regulator)
MEASURING CIRCUITS Alternator voltage
Nominal voltage : 90 ... 250 V AC / 250 ... 500 V AC
Frequency : 50 ... 400 Hz
Power consumption : 4 VA / 6 VA
Droop current sensing
(Voltage input)
Voltage at IN :3 ... 7 V AC
Power consumption : 0.15 ... 0.35 W
AUXILIARY CIRCUITS Supply voltage : 2 x single-phase 80 V AC 20 %
or
1 x three-phase 75 V AC 20 %
Power consumption : depending on excitation requirement
Nominal frequency : 50 ... 1200 Hz
OUTPUT CIRCUITS Actuator
Intermediate circuit voltage UZK : 85 to 130 V DC
(dependent on the supply voltage)
Continuous excitation current : 7 ADC (continuous)
Minimum field resistance RIK : 5(cold)
Minimum required
field time constant IK : 0.06 s
Short circuit exciter current : 20 ADC for 5 seconds
(at RIK = 5 and UZK = 100 VDC)
Protective fuse : 10 A-FF / 250 V – 6.3 x 32
ACCURACY Control accuracy : 1 % at 0 to 60 °C
5 % speed fluctuations and
apparent power 0 ... 100 %
TESTS Vibration test : German Lloyd category 2
EMV : CE-compliant in accordance with EN50081
and EN50082
AMBIENT CONDITIONS Storage temperature : - 40 ... + 70 °C
Operating temperature : -25 ... + 70 °C
(Special version "COSIMAT N+T"
- 55 ... + 70 °C)
HOUSING, DIMENSIONS,
WEIGHT AND INSTALLATION Height x width x depth : 121 x 115 x 162.5 mm
Fixing : 4 M6 bolts, washers and circlips
Weight : 2 kg
18
7. Dimensions
Figure 25 – Dimensions
19
8. Diagrams of connections
Legend for diagrams of connections
F1 Circuit breakers for G3
Operate only when stationary
G1 Main machine
G2 Exciter/excitation windings
G3 Auxiliary windings/Auxiliary exciter machine
R11/V3 Rotating varistor
T24 Voltage transformer for regulator
Must be disconnected if the star
point of G1 is open
T32 Voltage transformer for G3
with integrated circuit breaker F1
Operate F1 only when stationary!
V1 Rotating rectifier
X1 Main terminals
X2 – 6 Terminal strip
U1 "COSIMAT N+" voltage regulator
R3 Underspeed protection
R4 Internal desired value
R1 P component
S1 I component
R7 Droop adjustment
R6 Droop transformer matching
R1 Desired value potentiometer alternator
voltage (R = 500)
T6 Droop transformer
20
8.1 Assembly for DSG alternators 52 - 74
Figure 26 – Internal mounting, DSG alternators 52 – 74
Figure 27 – External mounting, DSG alternators 52 – 74
21
8.2 Assembly for DSG alternators 86 – 125
Figure 28 – Internal mounting, DSG alternators 86 – 125
Figure 29 – External mounting, DSG alternators 86 – 125
22
8.3 Assembly for DIG medium-voltage alternators with UN 11.5 kV
Figure 30 - Internal mounting, DIG medium-voltage alternators with U N 11.5 kV
Figure 31 - External mounting, DIG medium-voltage alternators with U N 11.5 kV
23
8.4 Assembly for DIG medium-voltage alternators with UN >11.5 kV
Figure 32 - Internal mounting, DIG medium-voltage alternators with U N > 11.5 kV
Figure 33 - External mounting, DIG medium-voltage alternators with U N > 11.5 kV
24
8.5 De-excitation circuit on the "COSIMAT N+"
If a de-excitation circuit is fitted, the bridges on the double
terminals UH1/UH1’ and WH1/WH1’ should be removed.
Switch contacts should be connected to the double terminals
to de-excite the alternator when they open (see Figure 34 –
De-excitation circuit). These de-excitation contacts must meet
the following specification:
Current carrying capacity:10 AAC
Voltage carrying capacity:160 V AC
The switch elements used must have dust-protected contact
chambers. Ensure that contact resistance is low – the contacts
must be sensitive to low-level signals.
Note:
One of the factors which determines the build-up of
excitation is the quality of these contacts.
On AvK alternators (DSG 86 – 125, DIG), connecting
terminals for de-excitation are provided in the auxiliary
terminal box (see legend of the order-specific circuit
diagram).
Figure 34 - De-excitation circuit
Figure 35 - Field current/field voltage monitoring
8.6 Monitoring field current and voltage on the
"COSIMAT N+"
The "COSIMAT N+" is provided with double terminals I1/I1’
and K1/K1’ to allow the exciter field to be connected. Bridge
I1/I1’ must be removed to allow the field current and voltage
to be monitored (see Figure 35 – Field current/field voltage
monitoring).
The measuring range for field voltage monitoring is 150 VDC;
for field current monitoring it is 10 ADC. Rotary coil or
moving-iron instruments are recommended. Under certain
conditions, digital instruments may give false readings.
Note:
In the case of AvK alternators (DSG 86 – 125, DIG),
there are connecting terminals for monitoring the field
current and voltage on terminal strip X2.
25
9. Connections, adjusting elements and
displays
9.1 Connections
Voltage supply:
UH1
UH2 (VH1)
WH1
WH2
4.8 x 0.8 mm flat plugs and/or 2.5 mm2/4mm Ø screw
terminals
Supply can be 2 x single-phase (80 V AC 20 %) or
three-phase (75 V AC 20 % external conductor voltage).
2 x single-phase = UH1-UH2, WH1-WH2
three-phase = UH1-VH1-WH1
For de-excitation circuits, the bridges on the double
terminals must be removed (see 8.5 De-excitation circuit
or order-specific circuit diagram).
Measuring alternator voltage:
U-V-W 250 to 500 V AC
U-V-W 90 to 250 V AC
6.3 x 0.8 mm flat plugs
The specified voltage ranges relate to the nominal external
conductor voltage of the alternator. For higher voltages,
appropriate measuring transducers with a design
rating of 10 VA should be connected on the input side
(see 3.3 Monitoring alternator voltage).
The applicable voltage range should be taken from the
order-specific circuit diagram. For DIG alternators with
UN >1 kV, the range 90 – 250 V AC is generally chosen.
Consult AvK before initial start-up if required.
Monitoring droop current:
k–I
4.8 x 0.8 mm flat plugs and/or 2.5 mm2/4 mm Ø screw
terminals
The droop current transformer must be installed in the "V"
phase of the alternator.
Internally load-relieved droop current transformers are
used in AvK alternators.
At the nominal current of the alternator, a voltage of 3 to
7 V AC is required at the terminals k – I (see 3.5 Droop
and 6. Technical Data).
Connecting leads to the transformer must be shielded if
the regulator is installed externally. Connecting leads to
the short-circuit droop switch (see 11.5 Droop switch)
should be shielded in all cases. The shield should be
earthed at one end on the "COSIMAT N+" (see 8.
Diagrams of connections).
Exciter field:
I1 – K1
4.8 x 0.8 mm flat plugs and/or 2.5 mm2/4 mm Ø screw
terminals as double terminal.
If the regulator is mounted externally, the I1/K1 field leads to
the alternator must be run through a separately shielded cable
(LSYCY or LIYCY).
The shield should be earthed at one end on the "COSIMAT N+"
(see 8. Diagrams of connections).
External set-point potentiometer
s–t
4.8 x 0.8 mm flat plugs and/or 2.5 mm2/4 mm Ø
screw terminals as double terminal.
The value of the set-point potentiometer determines the
adjustment range:
250 = about 5 %
500 = about 10 %
Caution:
Measuring input k – I is not a current input;
standard transformers should be load-relieved
accordingly.
Caution:
If there is an external power supply (e.g.
from the mains), it must not be switched on
until after the alternator has run up. It
should be switched off before the machine
has come to a halt (see 11.10 External
power supply).
Caution:
A clockwise rotary field is required. If the
alternator rotates anticlockwise, U and W
should be interchanged (see 3.5 Droop).
26
The rated power of the potentiometer must be at least 1
W. A multiple-turn potentiometer must be used (see 3.4
Desired value).
If the regulator or the set-point potentiometer is mounted
externally, the set-point lead must be provided with its
own separate shield. The shield should be earthed at one
end on the "COSIMAT N+". If the regulator is mounted
externally and the set-point leads are longer than >10 m,
a motor-actuated potentiometer should be used near to
the "COSIMAT N+".
Control inputs:
N
M/m
n
4.8 x 0.8 mm flat plugs and/or 2.5 mm2/4 mm Ø
screw terminals.
A number of additional modules from the "COSIMAT N+"
equipment range can be connected to these control
inputs (see 5.2 Additional modules).
The inputs have the following functions:
N Access to the internal actual value circuit
M/m Reference point for additional equipment
n Access to the internal desired value circuit
Circuit earth:
-
The circuit earth is likewise used as reference potential
for a number of ”controlling” additional modules.
This potential is not connected when the "COSIMAT N+"
is used for stand-alone operation.
Load earth:
Z
The load earth is used for connecting the internal intermediate
circuit capacitors.
Additional external capacitors can be connected between
the second Z connection tab (MINUS) and terminal I1
(PLUS).
This potential is not connected when the "COSIMAT N+"
is used for standalone operation.
9.2 Adjusting elements
Underspeed protection
R3
25-gang trim potentiometer
Function:
Adjustment of the frequency-dependent lowering of alternator
voltage (see 3.7.1 Underspeed protection).
Direction of action:
Left-hand stop = beginning of reduction at >50/60 Hz.
Right-hand stop = beginning of reduction only after
about > 30 Hz.
In special cases, the underspeed protection can be
deactivated by means of switch S2.2 (see 9.2 Adjusting
elements).
This is necessary when regulating a DC voltage by way
of additional module UDC or in some cases when using
external UF modules.
Desired value:
R4
25-gang trim potentiometer
Function:
Adjusting the alternator voltage (see 4.3 Desired value,
10.2 Desired value adjustment range).
Direction of action:
Left-hand stop = minimum alternator voltage
Right-hand stop = maximum alternator voltage
P component:
R1
1-gang trim potentiometer
Caution:
Before the "COSIMAT N+" is started up, R4
must be turned to the left-hand stop position
(see 10. Starting up the "COSIMAT N+"). A
regulator which is checked and delivered
together with an alternator is already preset.
Caution:
Only AvK additional modules must be used
at the control inputs. 20 mA standard signals
must not be used at these inputs.
27
Function:
Varying the proportional component of the control characteristic.
Direction of action:
Anticlockwise = small P component
Clockwise = large P component
The recommended adjustment range shown in Fig. 8 –
P adjustment range must not be exceeded (see 10.3
Regulating parameters).
I component:
S1
16-stage code switch
Function:
Varying the I component in the regulating characteristic
(see 10.3 Regulating parameters).
Direction of action:
Left (1 <- F) = small I component
Right (1 -> F) = large I component
Droop:
R7
1-gang trim potentiometer
Function:
Adjustment of the droop effect.
Direction of action:
Left-hand stop = no droop effect (0 %)
parallel operation not possible.
Right-hand stop = droop effect 6 %
If the direction of rotation is reversed, sensing voltage
connections U and W must be interchanged.
Droop matching:
R6
25-gang trim potentiometer
Function:
Matching the various alternator nominal currents and
current transformer ratios to the droop monitoring system.
Direction of action:
Left-hand stop = maximum compensation value
Right-hand stop = minimum compensation value
At nominal alternator current, R6 should be used to carry
out trimming to 2.5 V AC at the measuring points
”MP-STATIK – DROOP”. If the alternator load current is
less than the nominal current, this may be trimmed to a
proportional voltage value.
Code switch:
S2
4-pole dip switch
Function:
Switch FUNCTION ON OFF
S2.1 none ./. ./.
S2.2
Activation and
deactivation
of underspeed
protection
Active Not
active
S2.3
Reduction of
actual value
smoothing
Nominal Reduced
S2.4 Increasing the
D-parameter Increased Nominal
Required basic setting:
AvK DSG alternators up to size 62:
S2.1 = no function
S2.2 = ON (underspeed protection)
S2.3 = ON (actual value smoothing)
S2.4 = OFF (D parameter)
AvK DIG, DSG 74 – 125 alternators
S2.1 = no function
S2.2 = ON (underspeed protection)
S2.3 = ON (actual value smoothing)
S2.4 = ON (D parameter)
9.3 Displays
Underspeed protection:
H1
yellow 5 mm Ø LED
Caution:
Switch position ”0” is not permitted.
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H 1 lights up when the desired value or lowering of alternator
voltage in the case of underfrequency is active (3.7.1 Underspeed
protection)
10. Starting up the "COSIMAT N+"
10.1 Basic setting and visual check
Before start-up, the following basic settings of the "COSIMAT N+"
voltage regulator must be checked:
R3 right-hand stop position
R4 left-hand stop position
R1 central position
(in the case of DIG, DSG alternators, 1/4
rotation anticlockwise from the central position)
S1 Pos. 4
(in the case of DIG, DSG alternators Pos. 6,
at 600/750 rpm Pos. 9)
S2 S2.1 = no function
S2.2 = ON
S2.3 = ON
S2.4 = OFF (ON in the case of DIG and DSG
alternators from size 74)
R7 Central position
R6 Left-hand stop
After basic setting, the following visual checks must be carried
out:
a) Have the sensing voltage connections (U, V, W
90...250 / 250...500) been correctly selected?
b) Do the sensing voltage connections possess a clockwiserotating
field? (If rotation is anticlockwise, interchange U
and W).
c) Is the supply voltage correctly connected (2 x singlephase
UH1/UH2 and WH1/WH2; three-phase UH1,
VH1, WH1)?
d) Is the excess current circuit breaker in the alternator
switched on?
e) Is the droop transformer installed in the V phase?
f) Is the k – I phase position of the droop current transformer
correctly connected? (In the case of external installation,
check from the alternator to the regulator).
g) Is the field connected with the correct polarity?
10.2 Desired value setting range
Once all the basic settings and visual checks have been
carried out, the alternator can be started up.
a) Run up alternator to nominal speed.
b) Set external set-point potentiometer to the central position.
c) Adjust nominal voltage using R4.
d) The alternator voltage can be adjusted around its
nominal value using the external set-point potentiometer.
10.3 Regulating parameters
a) If the basic settings of R1 and S1 (see 10.1 Basic setting
and visual check) lead to continuous periodic fluctuations
(stability limit), adjust R1 slowly to the left.
b) If there is temporarily a tendency towards weakly
damped hunting in the event of load surges, adjust S1 one
or two positions to the right.
10.4 Underspeed protection
a) 50/60 Hz alternators to 0.95 x fN.
b) In the case of 50/60 Hz alternators, turn R3 slowly in
the anticlockwise direction starting from the right-hand stop
position until H1 lights up. Then turn it slowly in the clockwise
direction until H1 goes out.
c) Run the alternator up to nominal speed.
10.5 Droop adjustment
a) Load the alternator with nominal current. Measure the AC
voltage at the droop sensing points ”MP-STATIK-DROOP”.
Adjust to 2.5 V AC using potentiometer R6.
b) For partial loading, the calibration value can be reduced
proportionately.
c) If a stronger droop effect is required, R7 (percentage
droop) should be turned clockwise starting from its central
position.
Note:
Where a number of alternators are run in parallel, the
droop device must be at the same setting in all the
"COSIMAT N+" regulators and be active!
Caution:
The regulator is set during the testing of the
alternator at the factory. See test protocol
and order-specific circuit diagram.
29
Recommended droop settings:
3 % Parallel to the mains (If the mains supply is not
stable, the setting may have to be increased).
2 % Parallel operation with identical alternators.
6 % Parallel operation with different alternators whose
regulators do not have a linear droop.
1 % Parallel operation with different alternators which
also have "COSIMAT N” or ”N+" regulators.
11. Important notes
11.1 Protection concept for external mounting
of regulator
The following protective measures must be taken if the regulator
is installed externally in the switching station:
The sensing line U-V-W is to be laid using short-circuit-proof
cable (1.5 mm2) from the alternator terminal strip X2 to the
switching station. AvK recommends the installation of a
three-phase circuit breaker with a thermal tripping current of
approximately 0.5 A. If this circuit breaker is tripped, the
alternator must be de-excited and stopped immediately.
If the regulator is installed externally, the connecting leads for
the external set-point potentiometer, the droop current transformer,
the droop switch and the I1/K1 exciter line are to be
provided with separate shielding. The shields must be earthed
at one end on the "COSIMAT N+".
Protection concept:
The exciter system should be protected from excessive exciter
currents and voltages by a field discharge switch or relay.
This switch or relay should be connected as shown in the
relevant order-specific circuit diagram. The tripping criteria
will be determined by the protection required by the alternator.
Where the alternator is operated in stand-alone mode, an
overvoltage protection system must be installed in the switching
station. In the case of operation in parallel with the
mains or other alternators, an overcurrent protection system is
to be added.
DSG/DIG alternators with auxiliary windings:
DSG and DIG alternators with auxiliary windings are fitted
with an excess-current circuit breaker F1. This protects the
auxiliary windings from excessively high thermal loading e.g.
as the result of an external short circuit involving the auxiliary
exciter voltage UH1-UH2 or WH1-WH2.
11.2 Mounting the regulator
The "COSIMAT N+" must be mounted with its longitudinal
axis vertical in case of convectional cooling to allow the air
to flow freely through its power stage. Note the installation
position marking ”UNTEN” (= BOTTOM) (connecting
leads towards the power stage). At fan cooling, the longitudinal
axis of the "COSIMAT N+" has to be in air flow
direction. Deviating mounting is only suitable after checking
by AvK.
There must be a 3 cm clearance all the way round between
the "COSIMAT N+" and any structural elements that might
hinder flow (cable ducts, plates). This rule does not apply to
laterally mounted additional modules.
11.3 Excitation build-up
At the nominal speed, the auxiliary excitation windings on
DSG and DIG alternators must produce a remanent voltage
of at least 10 V AC in order to ensure a satisfactory excitation
build-up.
However, problems with excitation build-up may also be
caused by dirty de-excitation contacts or a field connection
of incorrect polarity.
In the case of alternators which have been stationary for a
prolonged period, it may be necessary to introduce an
external excitation voltage. To do this, a 4.5 V or 6 V battery
is briefly connected by its positive terminal to I1 and by its
negative terminal to K1 at nominal speed. In the case of
two-phase auxiliary excitation machines, the battery should
be connected to I2(POSITIVE)/K2(NEGATIVE).
11.4 Code switch S2
For standard applications of the "COSIMAT N+", the following
basic settings must be made before start-up at code switch S2
(see 9.2 Adjusting elements):
AvK DSG alternators up to size 62
S2.1 = no function
S2.2 = ON (underspeed protection)
S2.3 = ON (actual value smoothing)
S2.4 = OFF (D parameter)
AvK DIG and DSG 74 – 125 alternators:
S2.1 = no function
S2.2 = ON (underspeed protection)
S2.3 = ON (actual value smoothing)
S2.4 = ON (D parameter)
Any differences from these settings must be agreed with the
manufacturer beforehand and taken into account in the way
the alternator is operated.
11.5 Droop switch
If alternators are to be used for both single and parallel
operation, better voltage stability can be achieved in single
30
operation if the k – I inputs of the "COSIMAT N+" are
short-circuited (see 8. Diagrams of connections).
The lead between the droop switch and the regulator must be
screened.
The screen must be earthed at one end on the "COSIMAT N+".
11.6 Changing the direction of rotation
To enable the droop sensing system to exercise the correct
effect, the "COSIMAT N+" requires a clockwise-rotating field
at its measuring voltage connections.
Note:
The desired direction of rotation should be specified
when ordering the alternator. This is important with
regard to ventilation.
11.7 Synchronous motors
Synchronous motors operate in a similar way to synchronous
alternators in parallel operation. The direction of the active
power is rotated through 180° relative to the alternator (see
Figure 36 – Operation of the synchronous machine).
Starting from cos phi = 1, this has the following implications
for the reactive power:
l Given a rising exciter current (overexcitation), the synchronous
machine becomes a source of reactive power.
l Given a falling exciter current (underexcitation), the synchronous
machine becomes an acceptor of reactive power.
When used as a generator, the synchronous machine is taken
as the reference point; where it is used as a motor, the mains
are taken as the reference point.
When used as a generator, the synchronous machine supplies
”inductive” reactive power to the mains when overexcited.
When used as a motor, the synchronous machine draws
”inductive” reactive power from the mains when underexcited.
The droop system in the "COSIMAT N+" operates with the
correct direction of action whether the machine is being
operated as a motor or a generator. The direction in which
it is installed in the synchronous machine and the way the
droop current transformer is connected to the "COSIMAT N+"
remains the same (see 8. Diagrams of connections).
For motor control, a cos phi controller (COS module) is
required additionally.
Figure 36 – Modes of operation of a synchronous machine
11.8 Protective fuses
When the protective fuses are tripped, they must be replaced
with fuses of the same type.
Fuse type:
10 A super quick-acting IEC G 144.400
Two spare fuses are mounted on the underside of the "COSIMAT
N+" (see 7. Dimensions).
11.9 Drying out the alternator
If, because of inadequate insulation resistance, the alternator
has to be dried out at nominal current by the short-circuit
method, the "COSIMAT N+" should be disconnected from
the supply and exciter field connections.
The alternator is dried out by applying an external source of
excitation.
Further information on how to dry out the alternator can be
found in the alternator instructions.
Caution:
The power stage may be permanently damaged
if slow or medium time-lag fuses
with a rating equal to or higher than 10 A
are used!
Caution:
If the direction of rotation is reversed, interchange
sensing leads U and W.
Caution:
In parallel operation, the switch must be
opened.
31
11.10 External power supply
If the auxiliary exciter voltage is taken from a different,
”external” source (e.g. the mains), the supply must not be
switched on until the alternator has started up.
When shutting down the alternator, the supply must be
switched off before the machine comes to a halt.
The switch-on and switch-off point of the supply should be set
to 0.95 x fN using a frequency relay (BF1).
The double terminals at connections UH1 and WH1 can be
used to switch the supply on and off (see 8.5 De-excitation
circuit).
11.11 400 Hz alternator/converter
On 400 Hz alternators < 100 kVA (as single machines or
converters), switch S2.3 must be set to the "OFF" position.
11.12 Checking the insulation voltage of the
electric machine
Before checking the insulation voltage of the electric machine,
the following connections of the "COSIMAT N+" must be
disconnected:
Measuring voltage U, V, W
Supply UH1-UH2, WH1-WH2
Exciter field I1-K1
The supply and measurement connections of additional regulator
components must also be disconnected.
All disconnected or interrupted connections should be isolated
in the appropriate manner.
11.13 Exchange/replacement; "COSIMAT N/N3"
by "COSIMAT N+"
On AvK alternators of series DSG, DIDBN, DIDBH and DIG,
sizes ...74-86-99-114-125, switch S2.4 on the "COSIMAT
N+" should be switched to the ”ON” position. Switches S2.2
and S2.3 should be switched to the ”ON” position. Switch
S2.1 should be set to the ”OFF” position.
The sequence of terminals WH1 and WH1’ has been
reversed on the "COSIMAT N+". The connecting cable WH1
must be connected to the correspondingly named connecting
terminal of the "COSIMAT N+".
Caution:
When the alternator is stationary and an
auxiliary exciter voltage is applied, the
exciter current flowing is at its maximum!
The protective circuit of the "COSIMAT N+"
will trip the protection fuses on the front
plate after about 8 seconds.
32
Malfunction
Alternator voltage is too low.
Alternator voltage is too low and cannot
be adjusted with the set-point potentiometer.
Alternator voltage is too high.
Alternator voltage is too high and cannot
be adjusted with the set-point potentiometer.
Severe voltage dip upon loading.
Alternator does not respond to excitation.
Cause
Input speed too low.
Measuring leads incorrectly connected.
Set-point potentiometer or its connecting
leads are disconnected/interrupted.
Broken measuring lead.
Measuring leads incorrectly connected.
Set-point potentiometer or its connecting
leads have a short circuit.
Input speed falls upon loading.
Defective protection fuse.
Rotating diodes defective.
Input speed too low. Less than 0,5 x nN.
Exciter protection switch has tripped.
Remedy
Check whether LED H1 on regulator
lights up. If so, underspeed protection
device has been activated, run up alternator
to nominal speed.
Check measuring-lead connections U,
V, W on the regulator. Check whether
the nominal voltage of the alternator is
within the voltage range indicated on
the "COSIMAT N+".
Check set-point potentiometer or its
connecting leads. Rectify fault.
Rectify fault.
Check measuring lead connections U,
V, W on the regulator. Check whether
the nominal voltage of the alternator is
within the voltage range indicated on
the "COSIMAT N+".
Check set-point potentiometer for short
circuit. Change potentiometer. Check
set-point leads for short circuits. Eliminate
short circuit.
Check regulator of driving machine.
Check protection fuse on the regulator
and exchange if necessary.
Check rotating diodes V1 and surge
voltage protector V3 and R11 and
exchange if necessary.
Check the speed regulator of the input
machine. Check the power transmission
to the alternator.
Switch on the protective switch again.
If it trips once more, search for the fault
and repair it.
11.14 Malfunctions, causes and remedies
33
Malfunction
Alternator does not respond to excitation.
Periodic fluctuations in the alternator
voltage when operated singly (stability
limit)!
Cause
Remanence too low.
DSG, DIG alternators:
Interruption in the auxiliary exciter windings.
DIG alternators (UN 11,5kV):
Interruption in the auxiliary exciter
machine windings.
DSG, DIG alternators:
Interruption in exciter windings I1/K1.
DIG alternators (UN > 11.5 kV):
Interruption in exciter windings I1/K1
and/or I2/K2.
Fault in regulator.
Fault in the regulator connections.
Regulator defective.
Rotating diodes defective.
Incorrect regulator setting.
Remedy
Alternator with auxiliary winding:
Briefly connect positive terminal of 4.5
or 6 V battery to I1 and negative
terminal to K1 (at nominal speed).
Alternator with two-phase auxiliary
exciter machine:
Briefly connect positive terminal of 4.5
or 6 V battery to I2 and negative
terminal to K2 (at nominal speed).
With alternator standing still!
Check windings UH1/UH2 and
WH1/WH2 for interruptions using an
ohmmeter. Eliminate faults.
With alternator standing still!
Check windings WH1/WH2 and
UH2/UH1/UH3 for interruptions
using an ohmmeter. Eliminate faults.
With alternator standing still!
Check windings I1/K1 for interruptions
using an ohmmeter. Eliminate faults.
With alternator standing still!
Check windings I1/K1 and I2/K2 for
interruptions using an ohmmeter. Eliminate
faults.
Check protective fuses and exchange
if necessary. Is the regulator receiving
excitation release and are the bridges
present at the double terminals I1/I1’,
K1/K1’, UH1/UH1’ and WH1/WH1’?
Check and eliminate fault.
Check all regulator connections, input
and output leads. Eliminate faults.
Exchange regulator.
Check rotating diodes V1 and voltage
surge protector V3 and R11 and
exchange if necessary.
Adjust R1 carefully in the anticlockwise
direction and turn S1 one or two steps
to the right.
34
Malfunction
Alternator voltage fluctuates at irregular
intervals.
Reactive power output too high in parallel
operation.
Reactive power output too low in parallel
operation.
Active load not equally distributed.
Cause
Temporary interruption in one of the
regulator supply leads.
Mechanical regulator of the driving
machine is sticking.
Droop set too low.
Transformer connections k/I have
been bridged by the droop switch.
Phase angle connection (k/I) of the
droop current transformer has been
wrongly positioned.
Droop switch is not in alternator phase
”V”.
Measuring voltage connections U, V,
W wrongly positioned.
Droop set too high.
Measuring voltage connections U, V,
W wrongly positioned
This is affected by the driving machine
only.
The "COSIMAT N+" affects only the
reactive power.
Remedy
Check connecting leads to the regulator.
Check connections at the terminal
board of the alternator. Tighten all contact
screws and nuts.
Check speed regulator of the driving
machine. Eliminate fault.
Adjust R7 slightly in the clockwise direction
on the "COSIMAT N+".
Open bridge.
Check connecting leads from the alternator
to the regulator. Interchange k/I
if necessary. The white secondary connection
of the droop current transformer
is ”k”.
Install droop transformer in phase ”V”.
Check the sensing lead. "COSIMAT
N+" requires a clockwise-rotating field.
Interchange U and W if necessary (in
the case of anticlockwise rotation).
Adjust R7 slightly in the anticlockwise
direction on the "COSIMAT N+".
Check the sensing lead. "COSIMAT
N+" requires a clockwise-rotating field.
Interchange U and W if necessary (in
the case of anticlockwise rotation).
Check the drive motor and its regulator.
We reserve the right to make technical changes.
35
12. List of figures
Figure 1 General arrangement diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 2 Adjusting elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 4 Characteristic quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 5 Trend of the control property . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 6 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 7 Droop characteristic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 8 P adjustment range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 9 Underspeed protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 10 Equivalent control circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 11 Additional module COS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 12 Additional module QPF A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 13 Additional module QPF B . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 14 Additional module QPF C . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 15 Additional module SB2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 16 Additional module TF1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 17 Additional module ES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 18 Additional module UF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 19 Additional module UF3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 20 Additional module SR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 21 Additional module EI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 22 Additional module UDC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 23 Additional module KP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 24 Additional module ER1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 25 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 26 Internal mounting, DSG alternators 52 – 74 . . . . . . . . . . . . . . . . . . . . 21
Figure 27 External mounting, DSG alternators 52 – 74 . . . . . . . . . . . . . . . . . . . . 21
Figure 28 Internal mounting, DSG alternators 86 – 125 . . . . . . . . . . . . . . . . . . . 22
Figure 29 External mounting, DSG alternators 86 – 125 . . . . . . . . . . . . . . . . . . . 22
Figure 30 Internal mounting, DIG medium-voltage alternators with U N 11.5 kV . . . . . . . . 23
Figure 31 External mounting, DIG medium-voltage alternators with U N 11.5 kV . . . . . . . . 23
Figure 32 Internal mounting, DIG medium-voltage alternators with U N > 11.5 kV . . . . . . . . 24
Figure 33 External mounting, DIG medium-voltage alternators with U N > 11.5 kV . . . . . . . . 24
Figure 34 De-excitation circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 35 Field current/field voltage monitoring . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 36 Modes of operation of a synchronous machine . . . . . . . . . . . . . . . . . . . 31
36