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1. MM Three phase voltage transformer to supply excitation power and actual value measurement feedback to the AVR Current transformers to the supply excitation power in short circuit situations A digital AVR installed on its mounting plate Synchronous Generator Excitation System The main features of the synchronous generator excitation and regulation system include MB Automatic start up No external W Excitation for sustained short circuit ower source is required for initial l j _ a W Protection against over voltage excitation at start up Excitation current limiter MH Power factor control or voltage control with reactive droop compensation Static accuracy is better than 1 at all symmetric loads MB A frequency fall off feature preset Stepless voltage setting range to start reducing the voltage when 10 the frequency falls below 90 of the rated frequency A typical example of an AVR assembly for a brushless synchronous generator j 2 3 4 5 6 7 8 9 Generator current signal Generator voltage supply Booster supply Automatic regulator Rectifier Exciter Rotating rectifier Field windings Stator windings Synchronous Motor Excitation and Protection System Poe Oo BOW eC ale heey alge IN The main features of the synchronous motor excitation and protection system include Mi Power factor control or reactive MH Starting time supervision power c2. any installation even in chemical plants EEE Electrical Characteristics The electrical engineering of our syn chronous machines is based on a thorough knowledge of the rules of physics as they apply to all interactions between the driven machine and the electric network ii da pu oe E E Areas ce ee ee e ee a ee i E F Electrical optimization Modern state of the art software permits the analysis of all normal and abnormal conditions affecting the electric network or the driven machine Electrical characteristics are optimized to meet each customer s specific needs and requirements Pee PERE Synchronous Generator Excitation System Our generators are designed for self excitation and need no external sources of excitation mom O BE ULAG Af lei lee Aa eM The synchronous generator excitation and regulation system includes the following main components MM Three phase brushless exciter with rectifying diode bridge to supply DC current to the field windings Mi Automatic voltage regulator AVR to keep the terminal voltage or the power factor constant at a preset level under varying load conditions Both analog and digital AVRs are available E For installations requiring an AVR backup arrangement configurations with two AVRs one in operation and the other on stand by are available Changeover between the AVRs can be automatic or manual bys ee SUED
3. in a terminal box on the side of or under the machine The main terminals are brought in through an undrilled gland plate In all types of synchronous machines the auxiliary terminal boxes are located separately from the main terminal box All auxiliaries and detectors are wired to separate boxes Accessories Standard accessories included Bearing s with oil sight glass Main terminal box Auxiliary terminal box Pt 100 elements for stator winding and bearing temperature monitoring Anti condensation heaters Jacking screws Cooling air filters Pa RSOPDAUZOC ITERE AEE SWN Leakage detector and cooling air temperature detector Jacking screw Pt 100 bearing temperature detector and oil sight glass o D a a i i ay E at Optional Accessories and Tools IP Pt 1000 for air temperature monitoring Peat exchanger leakage indicator a m Cooling water flow control systems Bearing lubrication oil system with circulation oil pumps oil filter s oil cooler pressure and oil flow switches l m speed operation and starting ation and maintenance Special Accessories and Tools Disc brakes Vibration detectors and monitoring devices Position indicators Stator shifting devices Barring gear Lifting beam Lifting beam Speed measurement uni including absolute encoder pulse tachometer Testing Testing is intended
4. Just Name Your Need AMG and AMZ Synchronous Machines PRODUCT REVIEW Just Name Your Need BR OsD DU Cab he EER AMG and AMZ Synchronous Machines Type Designation Code Global Experience Power for Industry Output Ranges Key Features Electrical Characteristics 4 5 6 T 8 9 Synchronous Generator Excitation System 11 Synchronous Motor Excitation and Protection System IA Excitation by Brushless Exciter I Excitation by Slip Rings i Insulation LJ Windings amp Stator WA Rotor Poles amp Shaft 18 End Shield Bearing Frame I Intergrated Pedestal Bearing Frame yA Bearings YA Bearing Lubrication PPA Cooling and Enclosure YX Terminal Boxes yl Accessories yA Testing yas Documentation Provided by the Manufacturer Additional Information Production code EA Type of machine ah o Frame size ALL S Frame length code ay i H S Core length code Number of Haa iss ii IC IP combination MN S 4 Bearing type i Type of excitation 10 Mounting arrangement 11 1 2 AM 3 zZ 4 1250 5 M 6 M 7 08 8 P 9 S 10 E 11 A You are reading the Product Review of AMG and AMZ synchronous ma chines made by ABB Oy in Helsinki Finland This Product Review presents our entire range and its technical infor mation The contents are designed to help you select the right machine f
5. Speed RPM oe So e Ko Output MW E 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 Speed RPM Een OCD sU ee IT Efficiency Vibration Tolerance Mounting Cooling Design Overload margin Corrosion Protection Key Features The ABB way to design and manufac ture is unique It provides numerous benefits to both the end user and ABB It saves energy cuts operating costs and means more output for the same investment Boe Ve EAN Optimized synchronous machines of a smaller size save money by cutting energy consumption and shortening payback times Higher quality also means higher reliability All synchronous machines are designed to withstand vibration AMG generators withstand vibration of up to 20 mm s RMS This gives synchronous machines a longer mechanical life Single and two bearing designs ensure that our synchronous machines are suitable for all purposes and easy to install Vertical air outlets make it easier to collect heat from the roof This saves money and helps to keep the surroundings clean Air to water and air to air heat exchangers are optimized for each machine A high degree of standardization means short delivery times Our synchronous machines will withstand overloads according to standards or specific requirements Anti corrosion protection ensures that the machines can be used in
6. amme is specified by the customer and or PRODUCT REVIEW mole Ne Ny Special tests Sound level measurement ISO 3744 Sudden short circuit test IEC 34 4 IEEE 115 Measurement of the shaft voltage Wave form measurement IEC 34 1 IEEE 115 Load switching on off test Starting of the synchronous motor Polarization index IEEE 43 oe oO eS 2 NS Documentation provided by the manufacturer of synchronous machines AMG and AMZ Pole HOP IDE AUG VAs Clee ie OS ee oy Documentation MH Technical specification W User s manual Drawings and Diagrams where applicable Dimension drawing Cross section drawing Shaft with rotating masses drawing Bearing drawing Heat exchanger drawing Connection diagram Layout of connections drawing Main terminal box drawing Auxiliary terminal box drawing AVR connection diagram Rectifier bridge drawing Excitation panel single line diagram Excitation panel lay out drawing Excitation panel circuit wiring and cabling diagrams Brush gear and brush drawing Tachometer drawing Packing and transportation drawing Removing of transport locking and rotor positioning drawing Rotor installation and removal drawing Manufacturing Information WI Quality plan Mi Manufacturing schedule Mi Test program Mi Test reports p ORD AUG Pin eral ea Ni Just Name Your Need om TORD ULO pee i Se an For your notes AA ED ED FADED ABB Oy Ele
7. ange mounted sleeve bearings are standard with frame sizes 0710 0900 and 1120 Integrated pedestal sleeve bearings These are sleeve bearing that are attached to an integrated pedestal attached to the stator frame This permits easy one piece installation and reduces vibration levels by shortening the shaft and stiffening the pedestal Integrated pedestal sleeve bearings are standard with frame sizes 1250 1600 2000 and 2500 Bearing Lubrication Self lubrication by oil rings The lubricating oil is picked up by the internal surface of the oil ring and is transferred directly to the shaft Frictional heat is dissipated by radiation and convection only Therefore the ambient temperature must be taken into account during design to ensure adequate natural cooling Flood lubrication by an external oil supply The lubricating oil is circulated by an external oil supply system and if necessary cooled by a separate unit This is sometimes necessary when ring lubrication of the bearing is insufficient due to specific rotational speed requirements and high frictional losses Cooling and Enclosure There are three commonly used cooling arrangements open air air to water and air to air Enclosure Standard enclosures include the following degrees of protection IP21 IP23 IP44 P54 and IP55 Purging and pressurizing equipment is also available Open air cooling E Open air cooling can b j
8. attached to the shaft with a shrink fit The shaft ends are nor mally cylindrical or flang ed End Shield Bearing Frame Mi Frames 0710 0900 and 1120 are of modular type The stator core is welded into a cylinder after which the end modules are welded to the stator core The bearings are flange mounted on the end shields Mi The stator core end modules and end shields are made of fabricated steel and the design easily withstands vibration Mi Frames 1250 1600 2000 and 2500 are full frame models with stator frames made from fabricated steel The bearings are mounted on pedestals integrated with the frame for installation as a single unit Mi Frames with separate pedestal bearings are available on request These machines can be equipped with soleplates or base frames The various parts of these machines i e rotor bearings and accessories are normally assembled on site Bearings The most common construction is cations An oil sight glass and temper spherically seated sleeve bearings with ature detectors are standard on all either forced or self lubrication Roller sleeve bearings bearings can be used in certain appli Stat OE AU Cr ei ENNER p Flange mounted sleeve bearings a Fi D i E pir Ee fa A flange mounted sleeve bearing is attached to the end shield which is in turn attached to the stator frame This permits easy alignment of the synchronous machine Fl
9. ctrical Machines P O Box 186 Fl 00381 Helsinki Finland Tel 358 0 10 2211 Fax 358 0 10 22 22675 www abb com motors amp drives ABB quality and technical know how are recognized all over the world but that is not the main thing Our reputation as a reliable supplier is based on considering the custom er s needs and the requirements of the final application Right from the first contact through manufacturing to the delivery you find the same ABB professional attitude and skill 3BFP 000 002 RO101 REV C
10. des with a heat resistant inorganic coating Radial cooling ducts in the stator core ensure uniform and effective cooling of the stator LE i BEIT Ly hy ao cag i ante L Hiker i i pr r J F peher ee a o T _ 3 R e ee o d 7 r ie Sie a k a r E ra Ta a Bi i Cae ee arp l gn 16 2 POD ea eee 4 j am e a ys aren Sates eee Rotor Poles amp Shaft Rotor P The rotor comprises a shaft a hub for larger machines and salient poles All rotor assemblies are vacuum pressure impregnated VPI as complete units to ensure excellent insulation and mechanical strength After impregnation the complete rotor assembly is dynamically balanced on two planes All rotors are designed to withstand over speed specified in international Poles The poles are normally manufactured from 2 mm laminated steel sheet The sheets are pressed together with inserted steel bars which are welded to the ends plates The poles are secured to the shaft or hub by bolts from above or below or by means of a dovetail connection The poles are equipped with a copper or brass damper winding as well as a field winding of either enamelled copper wire or flat copper bars The shafts are manufac tured from forged or rolled steel and ma chined to exact specifi cations Rotors for ma chine frame sizes 1250 and greater are normally equipped with a sepa rate hub
11. ontrol Op E Excitation current limiter E Automatic or manual control o W Stator current limiter Pull out protection Wi PQ limiter for under excitation Mi Rotating diode monitoring Setpoint high and low limiters short circuit and cut off Ei P g W Stall protection based on speed measurement during start E Excitation over and under current protection A typical example of an excitation system for a brushless synchronous motor 1 Motor voltage signal 2 Motor current signal 3 Automatic regulator 4 Excitation power supply 5 Pull out protection 6 Stall protection 7 Exciter 8 Rotating rectifier 9 Field windings 10 Stator windings Excitation by Brushless 34i Both brushless excitation and excitation with slip rings and brushes are availa ble Brushless excitation is typically used in generators and fixed speed motor applications Explosive environ ments demand brushless excitation The exciter rotor windings are wound with enameled wire impregnated shrunk fit to the shaft and secured with a key The exciter is mounted inside the motor frame with access through removable inspection covers Excitation by Slip Rings Excitation with slip rings and brushes is typically used with variable speed motors The slip rings are installed separate from the main motor interior with access through removable inspec tion covers Flange mounted slip ring The slip rings and
12. or your application The type designation of the synchronous machines made by ABB Oy are AMG and AMZ The single symbols of the designation code are explained below AMZ 1250MM08 PSEA Stands for Alternating Current Machines Indicates the type of machine G generator Z motor Frame size shaft height in millimeters always 4 digits i e 0710 for 710 mm shaft Frame length Stator core length Number of poles always 2 digits i e 08 for 8 poles Stands for the IC IP combination D open W open weather protected P pipe ventilated L air to water cooled A air to air cooled M other Bearing type A roller S sleeve C combination N no bearings Type of excitation B with brushes E brushless I no excitation squirrel cage rotor M permanent magnet rotor Mounting arrangement 2 bearings feet raised cylindrical shaft end 2 bearings feet down cylindrical shaft end bearing feet raised flanged shaft end bearing feet down flanged shaft end 2 bearings feet raised flanged shaft end 2 bearings feet down flanged shaft end no bearings feet raised no shaft Azipod other SNxIMMIVONDY Global Experience ABB s excellent know how in engineer ing and design is the result of more than 100 year s experience Our man ufacturing is continually being im proved Our medium voltage AC ma chines up to 15 kV are at work in practically all indus
13. scosity epoxy resin High pressure in the tank forces the resin into the very smallest of pores The resin in the windings is cured in an oven at high temper atures to pro duce a stable high quality insulation Mi Excellent reliability All our synchronous machines have insulation designed to Class F require ments with the maximum hot spot temperature limit of 155 C Years of dependable operational experience in a wide variety of applications Proven system Since 1977 tens of thousands of our machines have been insulated using the McCl system and are operating succesfully all over the world Outstanding performance Mica insulation combined with special epoxy resin applied with the VPI process ensures long life performance a ea n Dn si Tih Mi i T SE ay iy MICADUR COMPACT INDUSTRY MCI insulation system Windings amp Stator Windings are made using the well established VPI technique in which the insulation is based on the use of mica The mica insulated conductor is first wound into coil loops which are then spread to form the coil Windings The coils are insulated with glass fibre reinforced mica tape The mica tape is applied by special taping machines to ensure high quality Each coil is individually voltage tested Stator The stator core is built from stacked high grade low loss laminated electric sheet steel insulated on both si
14. the mounting flange or hub are usually made of steel and are normally mounted as a single unit Slip ring units with brass rings as well as split flange mounted units are available on request The slip ring unit is equipped with brass connection pins facilitating installation The excitation current is transferred to the slip rings by brushes Hub mounted slip ring Insulation The insulation system used in all our synchronous machines is the MICADUR COMPACT INDUSTRY MCI system The MCI insulation sys tem is based on the Vacuum Pressure Impregnation VPI method which has Insulation Fabrication Process Our standard practice is to insulate wound stators and rotors as complete units This ensures that both the insulation and the mechanical properties of the windings are excellent which means that they can easily withstand prime mover induced vibrations and the mechanical stresses caused by transients such as short circuit a pera The VPI Process successfully demonstrated its depend ability over many years in thousands of machines of all types and has achieved worldwide recognition for its excellence After the stator or rotor has been wound the entire construction is dried to expel all moisture and solvents from the insulation Under vacuum all air and moisture is removed from the voids and pores of the insulation The windings are immersed in a low vi
15. to check the prop erties and performance of the machine and verify than they comply with the customer s requirements The standard test programmes are divided into three parts routine tests type tests and special tests The routine test pro gramme is carried out on every machine and is included in the price of the machine The type test is normally Routine Tests 1 16 and Type Tests 1 22 1 Visual inspection 2 Air gap measurement and clearance check of sleeve bearings 3 Insulation resistance measurement 4 Winding resistance measurement 5 Checking of temperature detectors and space heaters 6 Terminal markings and direction of rotation i Axial play for unlocked bearing 8 Bearing run 9 Vibration measurement 10 No load point 11 Short circuit point 12 High voltage tests 13 Over speed test for generator 14 Tests on voltage regulators fitted on synchronous generators 15 Tests on excitation cubicle of synchronous motors 50 60 Hz 16 Insulation resistance measurement 17 Moment of inertia 18 No load curve 19 Short circuit curve 20 Heat run test temperature rise test IEC 34 1 IEEE 115 21 Zero power factor test 22 Losses and efficiency performed in addition to routine tests classification societies Unless otherwise on one machine of a series of similar specified all tests are performed ac machines or at the request of the cording to standard IEC 34 customer The special test progr
16. tries around the _ manm Our specific know how combined with our global resources and multi domestic presence make ABB the first choice as a supplier of synchronous machines Power for Industry AMG and AMZ synchronous machines manufactured by ABB are used all over the world We design our machines to suit our customers applications Fe Ble LO Ce a et E ee SYNCHRONOUS MACHINES operate in Power Plants Generators Marine Propulsion Motors Generators Azipods Cycloconverter Motors Chemical Oil and Gas Industries Reciprocating Compressors Extruders Metal Industries Coilers Edgers Mill Stand Motors Mining Industry Crushers Grinders SAG and Ball Mills Hoists Mineral Processing Industries SAG and Ball Mills Pulp and Paper Industry Chippers Refiners Grinders Water Pumps Special Applications Wind Tunnel Motors Condensers MG sets Output Ranges ABB offers you one of the most com prehensive ranges of synchronous ma chines AMG and AMZ Our research and development ensures the best solution for each purpose Typical Output Ranges at Different Speeds E AMG Generators 7 Output MVA sed i 1000 1100 B 1300 1400 1500 1600 1700 1800 1900 Speed RPM E AMZ Motors for ERS te 010 900 Mi AMZ Variable Speed Motors 0 100 200 i010 400 to 0 0 600
17. used TEE the air in the immediate environmentis relatively clean and ae air circulation The cooling air is drawn in through air filters passed through the active parts of the synchronous machine and then exhausted to the environment Air to water or air to air cooling Air to water cooling or air to air cooling is used when the immediate environment prevents the free circulation of the cooling air The heat exchangers are made from high quality corrosion resistant materials and can be easily removed The synchronous machines is totally enclosed with air to water or air to air cooling and has shaft mounted or independent electrical fans to move the air through the cooling unit gpr Side mounted cable entry point pm T Mi i 3 _ F S l a E 5 Pa E j Ti a Pg q Terminal box for auxiliaries and detectors Transformers mounted on a mounting plate inside a top mounted terminal box Terminal Boxes PORT OID UG ETAR ENRE The locations of the terminal boxes in different frame sizes Min frame sizes 0710 0900 and 1120 the terminal box is located on top as standard and can be designed to allow cable entry form either the right or left side of the machine The standard method of cable entry is from below the box but alternative arrangement are available on request Min frame sizes 1250 1600 2000 and 2500 the terminals are usually located inside the frame or
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