Description and adjustment instructions

COSIMAT N+ voltage regulator

for DSG and DIG alternators
Description of COSIMAT N +
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Brief summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 G eneral diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Adjusting elem ents and their effects . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 O ptim ising the regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Pow er supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 M onitoring alternator voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4 Desired value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Droop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.6 C ontrol am plifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.7 Additional functions of the C O SIM AT N + . . . . . . . . . . . . . . . . . . . . . 10
3.7.1 U nderspeed protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.7.2 Protection functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.8 Pow er stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4. Transfer function of the COSIMAT N+ . . . . . . . . . . . . . . . . . . . . . . 12
5. Special functions and additional equipment . . . . . . . . . . . . . . . . . . . . 13
5.1 Stand-by and em ergency m anual sw itchover . . . . . . . . . . . . . . . . . . . . . 13
5.2 Additional m odules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7. Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8. Diagrams of connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.1 Assem bly for DSG alternators 52 74 . . . . . . . . . . . . . . . . . . . . . . . 21
8.2 Assem bly for DSG alternators 86 125 . . . . . . . . . . . . . . . . . . . . . . . 22
8.3 Assem bly for DIG m edium -voltage alternators w ith U N 11.5 kV . . . . . . . . . . . . 23
8.4 Assem bly for DIG m edium -voltage alternators w ith U N > 11.5 kV . . . . . . . . . . . . 24
8.5 D e-excitation circuit on the C O SIM AT N + . . . . . . . . . . . . . . . . . . . . . 25
8.6 M onitoring field current and voltage on the C O SIM AT N +. . . . . . . . . . . . . . 25
9. Connections, adjusting elements and displays . . . . . . . . . . . . . . . . . . . 26
9.1 C onnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.2 Adjusting elem ents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.3 Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10. Start-up of the COSIMAT N+ . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.1 Basic setting and visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.2 D esired value setting range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.3 Regulating param eters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.4 U nderspeed protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.5 Droop adjustm ent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11. Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.1 Protection concept for external m ounting of regulator . . . . . . . . . . . . . . . . . 30
11.2 M ounting the regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.3 Excitation build-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.4 C ode sw itch S2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.5 Droop sw itch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.6 C hanging the direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.7 Synchronous m otors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.8 Protection fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.9 D rying out the alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.10 External pow er supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
11.11 400 H z alternators and converters . . . . . . . . . . . . . . . . . . . . . . . . . 32
11.12 C hecking the insulation voltage of the electric m achine . . . . . . . . . . . . . . . . 32
11.13 Exchange/replacem ent; C O SIM AT N /N 3by C O SIM AT N + . . . . . . . . . . . 32
11.14 M alfunctions, causes and rem edies . . . . . . . . . . . . . . . . . . . . . . . . . 33
12. List of figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1. General
The C O SIM AT N +is a com pact voltage regulator designed
to control synchronous alternators both in single and parallel
operation.
In single operation, the alternator voltage is held constant
irrespective of pow er, frequency and tem perature.
W hen operated in parallel w ith the m ains or w ith other
alternators, a stable reactive pow er is produced.
Via its pow er stage, the C O SIM AT N +adjusts the excitation
current to m atch the operating conditions.
The m ain features of the C O SIM AT N +are:
G Integrated m easuring transform ers for three-phase m eas-
urem ent of the alternator voltage up to 500 V AC
(external conductor voltage).
G Stable reactive pow er thanks to current-voltage vector
m easuring system (droop). A load-relieved current trans-
form er is required in alternator phase V.
G Internal and external alternator voltage set-point ad-
justm ent.
G PID control am plifier w ith large adjustm ent range.
G Disproportionate drop in desired value w hen alternator
operates at underfrequency.
G Perm anent m onitoring of the actuator and tim e lim it on
the m ax. possible excitation current.
G Internal protection devices trip w henever a fault occurs,
thus separating the excitation field from its energy source.
G C om pact construction w ith interchangeable pow er
stage.
G Fully potted in to protect it from environm ental effects.
G Long life thanks to high-quality com ponents.
W ith the use of additional m odules it is possible to intervene
in set-point and actual value form ation via the C O SIM AT N +
signal inputs:
There are a large num ber of additional m odules available for
a w ide variety of control applications e.g.
G cos phi regulation of a synchronous alternator or m otor
or
G Lim itation of start-up current w hen connecting up a large
asynchronous m otor to the alternator
or
G C able com pensation via load current detection or m ea-
sured value of the external alternator voltage.
Its additional m odules m ake the "C O SIM AT N +" suitable for
various applications on test rigs, in pow er-train technology
etc. (see 5.2 Additional m odules).
2
2. Brief summary
2.1 General-arrangement diagram
Figure 1 G eneral-arrangem ent diagram
3
2.2 Adjusting elements and their effects
Figure 2 Adjusting elem ents
4
2.3 Start-up
Figure 3 - Start-up
5
2.4 Optimisation of the regulator
To optim ise regulation, it is necessary to connect loads to the
alternator.
To allow the trend of the control property follow ing a change
in the P or I param eter to be evaluated, the load connected
m ust be reproducible.
The factor w ith the greatest general significance in achieving
an optim um regulating system is an overshoot am plitude xm
w hich is as sm all as possible. The essential criterion in the
evaluation of the regulating process w ith respect to tim e is the
settling tim e taus.
To follow the trend of the control property, use an oscilloscope
to m onitor the m anipulated variable.
The "C O SIM AT N +" regulator allow s freeadjustm ent of the
P and I param eters. The D param eter can be sw itched over
in tw o stages using code sw itch S2.4.
Figure 4 C haracteristic quantities of the regulating system
Figure 5 Trend of the control property
It is not necessary to adjust the D param eter in order to
optim ise the control properties. It is generally determ ined just
once, in accordance w ith the size of the alternator. In the case
of alternators > 1 M VA, sw itch S2.4 is sw itched to the O N
position.
To decide w hether the D param eter should be increased
beyond this, it is necessary to take specific m easurem ents of
the alternator voltage and at the output of the regulator.
Satisfactory optim isation of the regulator w ill norm ally be
achieved by the free adjustm ent of the P and I param eters.
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3.2 Power supply
Pow er is supplied to the "C O SIM AT N +" by m eans of
so-called auxiliary excitation voltages, w hich are produced
in the alternators. The excitation energy and the supply
voltage for the "C O SIM AT N +" are derived from the auxiliary
excitation voltages.
In the case of AvK alternators in Series D SG and D IG w ith
U N 11.5 kV, the "C O SIM AT N +" is supplied w ith pow er
via tw o single-phase auxiliary w indings, w hich are inserted
into the m ain stator. The w indings are designated U H 1/U H 2
and W H 1/W H 2.
The voltages U H 1 and U H 2 are offset by 90 w ith respect
to W H 1 and W H 2 and are 80 V AC 20 % at the nom inal
voltage of the alternator.
In the case of AvK alternators belonging to Series DIG w ith
U N > 11.5 kV, the "C O SIM AT N +" is supplied w ith pow er
via a tw o-phase auxiliary exciter m achine. The w indings are
designated U H 1, U H 2, U H 3 and W H 1, W H 2.
The voltages U H 1 and U H 2 are offset by 90 w ith respect
to W H 1 and W H 2 and are 80 V AC 20 % at the nom inal
speed of the m achine.
The above-m entioned auxiliary exciter w indings U H 1 and
U H 2 and W H 1 and W H 2 are plugged into the correspon-
dingly designated term inals of the "C O SIM AT N +":
Special application
Three-phase auxiliary exciter machine
If a three-phase auxiliary exciter m achine is used, the w inding
term inals are designated U H 1-VH 1-W H 1. The external con-
ductor voltage is 3 x 75 V AC 20 % at the nom inal speed
of the m achine.
Special application
External power supply
The "C O SIM AT N +" can also be operated w ith a constant
external voltage. It is generally supplied via a three-phase
transform er (Yy 0) w ith a secondary voltage of 3 x 75 V AC
20 % . The nom inal pow er should be at least 500 VA.
3.3 Monitoring alternator voltage
The "C O SIM AT N +" m easures alternator voltages from 90 to
500 V AC (external conductor voltage) w ithin tw o selectable
ranges by m eans of an internal three-phase m easuring trans-
form er.
To m easure higher voltages, corresponding voltage transfor-
m ers m ust be connected in series.
Signal input N allow s intervention into the internal form ation
of the actual value.
The secondary AC m easurem ent voltage of the m easuring
transform er is converted into a DC voltage, sm oothed, condi-
tioned and output as an actual value to the regulator circuit.
The m easured value w hich is produced corresponds to the
arithm etic m ean of the rectified three-phase AC m easurem ent
voltage.
Three-phase m easurem ent allow s for asym m etric loads.
Note:
For non-linear loads (static thyristor converter or rectifier),
additional m odule TF (RC low -pass filter) is recom m ended
as a m easuring adapter. H igh non-linear loads m ay
require overdim ensioning of the alternator.
3.4 Desired value
The desired value for the "C O SIM AT N +" is taken from a
tem perature-com pensated reference source.
The signal input nallow s intervention in the internal form ation
of the desired value.
The reference voltage reaches the set-point potentiom eter R 4
m ounted on the front end of the "C O SIM AT N +". This
potentiom eter allow s coarse adjustm ent of the alternator
voltage over a w ide range (= approxim atedesired value).
In parallel operation of the alternator, the reference voltage
is influenced by the droop-m easuring system (see 3.5 D roop)
and, in the case of underfrequency, by the underspeed
protection.
A set-point potentiom eter can be connected to the "C O SIM AT N +"
for external adjustm ent of the desired value.
This potentiom eter is used for fine adjustm ent of the alternator
voltage (= exactdesired value).
The adjustm ent range is lim ited to 5 % to 10 % around
the nom inal value, depending on the potentiom eter used.
The ES additional m odule allow s the adjustm ent range of the
external set-point potentiom eter to be extended from rem anence
to the nom inal voltage.
Caution:
If the auxiliary excitation voltage is taken
from a constant "external" power source (e.g.
the mains), the supply must be switched on
only after the alternator has been started.
When switching off the alternator, the
supply should be switched off before the
machine comes to a halt (see 11.10 External
power supply).
8
If the ES m odule is used on AvK alternators, the regulator
system m ust be provided w ith an external pow er supply. This
m ust be decided on a case by case basis, depending on the
application and the excitation system used (auxiliary excitati-
on w indings or auxiliary excitation m achine?)
3.5 Droop
O nce an alternator has been connected in parallel, voltage
regulation is no longer possible because the system voltage
is fixed. The slightest fluctuation in the system voltage w ould
lead to the alternator producing reactive current > IN .
To stabilise the alternator reactive current it is therefore
necessary to have a m easured variable w hich is dependent
on the reactive current and incorporates the m agnitude of the
current and the reactive pow er (inductive or capacitive). This
m easured variable is introduced at the addition point (com -
parison point of the desired value and the actual value) of the
control am plifier circuit.
This produces a static droop control characteristic, w hich
represents the relationship betw een:
the change in the alternator voltage in relation to the nom inal
voltage and
the change in the alternator reactive current in relation to the
nom inal current.
The droop is represented by the slope of the characteristic
curve produced i.e. is the quotient of the above ratio.
In the "C O SIM AT N +" a linear droop characteristic is gene-
rated. The droop effect can be adjusted from 0 to 6 % using
the potentiom eter R 7.
Exam ple:
In the case of an inductive reactive current of 100 % of the
nom inal current of the alternator and w ith the droop set to 6 %,
the alternator voltage is reduced by 6 %.
Figure 7 D roop characteristic
If, w hen the alternator is connected in parallel, the fixed m ains
forces it dow n to a figure w hich is 6 % low er, the reactive
current is inductive and equivalent to 100 % of the nom inal
alternator current.
In parallel operation, regulation of the synchronous alternator
is m ade possible by the droop sensing signal.
For stand-alone operation, adjustm ent is perform ed on the test
rig using a reactive load. The droop effect is set to 3 % .
The droop sensing signal in the "C O SIM AT N +" influences
the desired value and is produced by m eans of a geom etrical
addition of the external conductor voltage U -W and a
current-dependent voltage signal from the V phase.
In AvK synchronous m achines, the corresponding current
transform er is located in phase V. The K side of the transfor-
m ers points tow ards the alternators m ain w inding (see Figure
6 Block diagram ).
Internally load-relieved bushing-type transform ers are used.
The outlet end of the secondary connections ( = potted end
of the transform er) is the prim ary-side K point (= current input).
The w ire m arked in w hite is the secondary-side k point.
The secondary connections k and I of the droop current
transform er should be plugged into the correspondingly m ar-
ked term inals of the "C O SIM AT N +".
In the case of alternators for parallel and stand-alone opera-
tion, the m easuring input k I can be short-circuited by m eans
of a sw itch for stand-alone operation. This gives better voltage
stability (see 8. Diagram s of connections, 11.5 D roop
sw itch).
The droop sensing system of the "C O SIM AT N +" is m atched
to the nom inal current of the alternator by m eans of potentio-
m eter R 6.
3.6 Control amplifier
The control am plifier of the "C O SIM AT N +" has a PID
characteristic. The param eter of the I section can be varied
in steps from 1 to F using sw itch S 1. D uring this process, the
integration tim e constant increases.
Caution:
For the droop sensing system to function
correctly, the "COSIMAT N+" requires a
clockwise rotating field at its measurement
voltage terminals. If the direction of rotation
is reversed, measuring leads U and W
should be interchanged.
9
The param eter of the P section can be varied by m eans of
potentiom eter R 1. D uring this process, the adjustm ent range
show n in Figure 8 should not be exceeded.
Figure 8 P adjustm ent range
Further adjustm ent in the clockw ise direction leads to hunting,
w hile further adjustm ent in the anticlockw ise direction leads
to control errors.
The D param eter can be changed by sw itching code sw itch
S2.4 to the O N position. This increases the effect of the D
param eter, as required by larger alternators (DIG and DSG
74 ... 125).
The D param eter can furtherm ore be varied at the D -O pt.
optim isation points. At the specified polarity, a capacitor can
additionally be soldered in.
W hen installing additional D -section capacitors, it is im portant
to note their polarity (electrolyte capacitor) and nom inal
voltage (= 35 V DC ). The m axim um recom m ended value is
150 F.
3.7 Additional functions of the "COSIMAT N+"
3.7.1 U nderspeed protection
W hile a drive m achine (m otor or turbine) is w arm ing up, the
alternator is operated at underfrequency. To prevent overexci-
tation and therm al dam age in the exciter system , the "C O SI-
M A T N +" allow s frequency-dependent reduction of the
regulators desired value or alternator voltage in accordance
w ith a linear function (see Figure 9 U nderspeed protection).
The point at w hich the voltage drops is defined by a corre-
sponding frequency value set by m eans of R3. The reduction
for underspeed is indicated by H 1. Before delivery, the U /f
kink pointis set to 0.95 x fN . Above the kink point, voltage
regulation is constant.
The voltage reduction is delayed by about 2 seconds to
elim inate the effect of transient drops in the speed of the drive
m achine.
In exceptional circum stances, the underspeed protection fun-
ction can be deactivated by m eans of code sw itch S2.2 (see
9.2 Adjusting elem ents).
The underspeed protection function is active on 50/60 H z
alternators. For other nom inal frequencies, the U F m odule
should be used or the alternator should be deexcited w hen
being shut dow n.
Figure 9 U nderspeed protection
3.7.2 Protective functions
The auxiliary exciter w indings (see 3.2 Pow er supply) have a
very high short-circuit capacity. If the actuator is faulty, the
high short-circuit pow er involved m ay cause severe dam age.
To prevent this dam age, the "C O SIM AT N +" has tw o protecti-
ve functions w hich m onitor its actuator and prevent overloa-
ding of the exciter system :
Caution:
For standard applications of the "COSIMAT N+",
the underspeed protection function must be
active and correctly set. Code switch S2.2
must be in the ON position.
Caution:
Switch position 0 is not allowed; never pass
through 0.
10
Time limitation of the maximum excitation cur-
rent
W hen the actuator is fully on, the excitation current
reaches a m axim um .
If this state is allow ed to continue, the exciter system w ill
be dam aged.
H ow ever, the fully-on state only occurs in the case of
com pensating processes or short circuits at the m ain
term inals of the alternator.
The m onitoring system of the "C O SIM AT N +" lim its
m axim um excitation to 8 to 10 seconds.
After this, the protection circuit isolates the exciter field
from the source of excitation energy by tripping the
protection fuses.
Checking the direction of action of the control
amplifier and the actuator
This feature m onitors the positioning transistor for short
circuits.
Short-circuiting of the positioning transistor leads to m axi-
m um excitation. The control am plifier tries to counteract
this but has no effect on the faulty actuator. The actuator
and the control am plifier act in opposite directions and
the fuses trip im m ediately.
The follow ing circum stances also lead to m axim um excitation
and can trip the fuses:
G Faulty sensor leads
G D eactivated or incorrectly adjusted underspeed protecti-
on function
G Short circuit in the I1 / K1 exciter lead
G Faulty exciter rectifier in the "C O SIM AT N +"
G Extrem e overloading of the alternator (short circuit) if this
has not been sw itched off after 8 to 10 seconds.
The protection device integrated into the "C O SIM AT N +"
responds to a large num ber of defects and faults.
Note:
Additional m odule ER1 can be used to lim it the excitation
current w hen the alternator is operated in parallel.
3.8 Power stage
The pow er stage of the "C O SIM AT N +" provides an excita-
tion current that corresponds to the output signal of the control
am plifier.
A M O SFET transistor is used as the actuator, w ith pulse w idth
m odulation, i.e. the turn-on tim e varies but the sw itching
frequency rem ains constant.
The excitation energy is taken from the rectified supply
voltage, the rectifier circuit being located in the pow er stage.
It allow s the rectification of tw o single-phase or three-phase
supply voltages (see 3.2 Pow er supply).
There is a short-circuit thyristor in the D C circuit. The protective
circuit of the "C O SIM AT N +" sw itches this thyristor on if faults
occur in the control circuit. The resulting short-circuit current
trips the tw o protection fuses on the front plate of the "C O SI-
M AT N +" and the exciter field is isolated from the source of
excitation energy.
Fuse:
10 A super quick-acting
32 m m x 6.3 m m
IEC G 144.400
The pow er stage is located on a profiled heat sink. It is
plugged into the regulator and screw ed into the substructure
of the "C O SIM AT N +".
To ensure adequate cooling for the pow er sem i-conductors in
the pow er stage, you m ust follow the instructions in C hapter
11.2 M ounting the regulator.
Caution:
Replacement fuses must be of the above type.
The power stage may suffer permanent dama-
ge if the wrong type of fuse is used.
11
4. Transfer function of the "COSIMAT N+"
Figure 10 Equivalent control circuit diagram
There are three w ays of influencing the control param eters in
the "C O SIM AT N +:
Potentiom eter R1 (500 k) for changing the P param eter. At
the right-hand stop, R1 is 0.
Sw itch S1 for changing the I param eter in 15 steps (from 0.22
to 3.85 F) each of 0.22 F (C 1).
C ode sw itch S2.4 for increasing the D param eter from 10.1 F
(S2.4 = O FF) to 32.1 F (S2.4 = O N ) (C 2).
The individual param eters in the equivalent circuit diagram
(see Figure 10 Equivalent control circuit diagram ) can be
calculated as follow s:
T1 = R1 x C 1
T2 = 6,8 k x C 2
T3 = 22 k x C 1
TI = T1 + T2
TD =
K1 =2,56
K2 =
K3 = = 0,066
The tim e constant of the input low -pass filter is:
TP1 = 3.62 m s
The tim e constant of the output low -pass filter is:
TP2 = 0.268 x T2
T1 + T2
T3
716,1 m s x K1
T
T1 x T2
T1 + T2
1
15
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12
5. Special functions and additional
equipment
5.1 Stand-by and emergency manual switchover
W here higher availability is required, there are stand-by
circuits.
Stand-by circuits contain tw o "C O SIM AT N +" voltage regula-
tors.
The alternator is regulated by one of these regulators (m ain
regulator). If this regulator is defective, it is possible to sw itch
to the second (stand-by) regulator.
Stand-by circuits are available in either m anual or autom atic
form .
Manual stand-by circuit (SB1)
In the event of a m alfunction, a changeover sw itch perm its
the stand-by regulator to be selected.
The changeover sw itch sw itches over all the signals apart
from the sensing voltage and supply connections U H 2
(VH 1) and W H 2.
Automatic stand-by circuit (SB2)
The stand-by circuit m onitors the m ain regulator.
C om m on operating variables w ith respect to the response
of the regulator allow fault detection and sw itchover to
the stand-by regulator.
The stand-by regulator operates in sim ulated control
m ode and is likew ise m onitored.
The sw itch betw een the tw o regulators can take place
during the operation of the alternator and can be perfor-
m ed m anually, by m eans of a test function or, in the case
of a m alfunction, autom atically.
13
6. Technical data
GENERAL DATA Type : fully potted alum inium housing incl. pow er stage
M aintenance : m aintenance-free
Rated sw itch-on tim e : continuous operation
Installation position : m ount w ith 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 M ounting the regulator)
MEASURING CIRCUITS Alternator voltage
N om inal voltage : 90 ... 250 V AC / 250 ... 500 V AC
Frequency : 50 ... 400 H z
Pow er consum ption : 4 VA / 6 VA
Droop current sensing
(Voltage input)
Voltage at IN : 3 ... 7 V AC
Pow er consum ption : 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 %
Pow er consum ption : depending on excitation requirem ent
N om inal frequency : 50 ... 1200 H z
OUTPUT CIRCUITS Actuator
Interm ediate circuit voltage U ZK : 85 to 130 V D C
(dependent on the supply voltage)
C ontinuous excitation current : 7 AD C (continuous)
M inim um field resistance RIK : 5 (cold)
M inim um required
field tim e constant IK : 0.06 s
Short circuit exciter current : 20 AD C for 5 seconds
(at RIK = 5 and U ZK = 100 VDC )
Protective fuse : 10 A-FF / 250 V 6.3 x 32
ACCURACY C ontrol accuracy : 1 % at 0 to 60 C
5 % speed fluctuations and
apparent pow er 0 ... 100 %
TESTS Vibration test : G erm an Lloyd category 2
EM V : C E-com pliant in accordance w ith EN 50081
and EN 50082
AMBIENT CONDITIONS Storage tem perature : - 40 ... + 70 C
O perating tem perature : -25 ... + 70 C
(Special version "C O SIM AT N +T"
- 55 ... + 70 C )
HOUSING, DIMENSIONS,
WEIGHT AND INSTALLATION H eight x w idth x depth : 121 x 115 x 162.5 m m
Fixing : 4 M 6 bolts, w ashers and circlips
W eight : 2 kg
18
7. Dimensions
Figure 25 Dim ensions
19
8. Diagrams of connections
Legend for diagrams of connections
F1 C ircuit breakers for G 3
Operate only when stationary
G1 M ain m achine
G2 Exciter/excitation w indings
G3 Auxiliary w indings/Auxiliary exciter m achine
R11/ V3Rotating varistor
T24 Voltage transform er for regulator
Must be disconnected if the star
point of G1 is open
T32 Voltage transform er for G 3
w ith integrated circuit breaker F1
Operate F1 only when stationary!
V1 Rotating rectifier
X1 M ain term inals
X2 6 Term inal strip
U1 "C O SIM AT N +" voltage regulator
R3 U nderspeed protection
R4 Internal desired value
R1 P com ponent
S1 I com ponent
R7 Droop adjustm ent
R6 Droop transform er m atching
R1 D esired value potentiom eter alternator
voltage (R = 500)
T6 D roop transform er
20
8.1 Assembly for DSG alternators 52 - 74
Figure 26 Internal m ounting, D SG alternators 52 74
Figure 27 External m ounting, D SG alternators 52 74
21
8.2 Assembly for DSG alternators 86 125
Figure 28 Internal m ounting, D SG alternators 86 125
Figure 29 External m ounting, D SG alternators 86 125
22
8.3 Assembly for DIG medium-voltage alternators with UN 11.5 kV
Figure 30 - Internal m ounting, DIG m edium -voltage alternators w ith U N 11.5 kV
Figure 31 - External m ounting, D IG m edium -voltage alternators w ith UN 11.5 kV
23
8.4 Assembly for DIG medium-voltage alternators with UN >11.5 kV
Figure 32 - Internal m ounting, DIG m edium -voltage alternators w ith U N > 11.5 kV
Figure 33 - External m ounting, DIG m edium -voltage alternators w ith 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
term inals U H 1/U H 1and W H 1/W H 1should be rem oved.
Sw itch contacts should be connected to the double term inals
to de-excite the alternator w hen they open (see Figure 34
De-excitation circuit). These de-excitation contacts m ust m eet
the follow ing specification:
C urrent carrying capacity:10 AAC
Voltage carrying capacity:160 V AC
The sw itch elem ents used m ust have dust-protected contact
cham bers. Ensure that contact resistance is low the contacts
m ust be sensitive to low -level signals.
Note:
O ne of the factors w hich determ ines the build-up of
excitation is the quality of these contacts.
O n AvK alternators (D SG 86 125, DIG ), connecting
term inals for de-excitation are provided in the auxiliary
term inal box (see legend of the order-specific circuit
diagram ).
Figure 34 - De-excitation circuit
Figure 35 - Field current/field voltage m onitoring
8.6 Monitoring field current and voltage on the
"COSIMAT N+"
The "C O SIM AT N +" is provided w ith double term inals I1/I1
and K1/K1to allow the exciter field to be connected. Bridge
I1/I1m ust be rem oved to allow the field current and voltage
to be m onitored (see Figure 35 Field current/field voltage
m onitoring).
The m easuring range for field voltage m onitoring is 150 VD C ;
for field current m onitoring it is 10 AD C . Rotary coil or
m oving-iron instrum ents are recom m ended. U nder certain
conditions, digital instrum ents m ay give false readings.
Note:
In the case of AvK alternators (D SG 86 125, DIG ),
there are connecting term inals for m onitoring the field
current and voltage on term inal strip X2.
25
9. Connections, adjusting elements and
displays
9.1 Connections
Voltage supply:
UH1
UH2 (VH1)
WH1
WH2
4.8 x 0.8 m m flat plugs and/or 2.5 m m
2
/4m m screw
term inals
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 = U H 1-U H 2, W H 1-W H 2
three-phase = U H 1-VH 1-W H 1
For de-excitation circuits, the bridges on the double
term inals m ust be rem oved (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 m m flat plugs
The specified voltage ranges relate to the nom inal exter-
nal conductor voltage of the alternator. For higher volta-
ges, appropriate m easuring transducers w ith a design
rating of 10 VA should be connected on the input side
(see 3.3 M onitoring alternator voltage).
The applicable voltage range should be taken from the
order-specific circuit diagram . For DIG alternators w ith
U N >1 kV, the range 90 250 V AC is generally chosen.
C onsult AvK before initial start-up if required.
Monitoring droop current:
k I
4.8 x 0.8 m m flat plugs and/or 2.5 m m
2
/4 m m screw
term inals
The droop current transform er m ust be installed in the "V"
phase of the alternator.
Internally load-relieved droop current transform ers are
used in AvK alternators.
At the nom inal current of the alternator, a voltage of 3 to
7 V AC is required at the term inals k I (see 3.5 D roop
and 6. Technical Data).
C onnecting leads to the transform er m ust be shielded if
the regulator is installed externally. C onnecting leads to
the short-circuit droop sw itch (see 11.5 D roop sw itch)
should be shielded in all cases. The shield should be
earthed at one end on the "C O SIM AT N +" (see 8.
Diagram s of connections).
Exciter field:
I1 K1
4.8 x 0.8 m m flat plugs and/or 2.5 m m
2
/4 m m screw
term inals as double term inal.
If the regulator is m ounted externally, the I1/K1 field leads to
the alternator m ust be run through a separately shielded cable
(LSYC Y or LIYC Y).
The shield should be earthed at one end on the "C O SIM AT N +"
(see 8. Diagram s of connections).
External set-point potentiometer
s t
4.8 x 0.8 m m flat plugs and/or 2.5 m m
2
/4 m m
screw term inals as double term inal.
The value of the set-point potentiom eter determ ines the
adjustm ent 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 pow er of the potentiom eter m ust be at least 1
W . A m ultiple-turn potentiom eter m ust be used (see 3.4
Desired value).
If the regulator or the set-point potentiom eter is m ounted
externally, the set-point lead m ust be provided w ith its
ow n separate shield. The shield should be earthed at one
end on the "C O SIM AT N +". If the regulator is m ounted
externally and the set-point leads are longer than >10 m ,
a m otor-actuated potentiom eter should be used near to
the "C O SIM AT N +".
Control inputs:
N
M/ m
n
4.8 x 0.8 m m flat plugs and/or 2.5 m m
2
/4 m m
screw term inals.
A num ber of additional m odules from the "C O SIM AT N +"
equipm ent range can be connected to these control
inputs (see 5.2 Additional m odules).
The inputs have the follow ing functions:
N Access to the internal actual value circuit
M/ m Reference point for additional equipm ent
n Access to the internal desired value circuit
Circuit earth:
-
The circuit earth is likew ise used as reference potential
for a num ber of controllingadditional m odules.
This potential is not connected w hen the "C O SIM AT N +"
is used for stand-alone operation.
Load earth:
Z
The load earth is used for connecting the internal interm e-
diate circuit capacitors.
Additional external capacitors can be connected betw een
the second Z connection tab (M IN US) and term inal I1
(PLU S).
This potential is not connected w hen the "C O SIM AT N +"
is used for standalone operation.
9.2 Adjusting elements
Underspeed protection
R3
25-gang trim potentiom eter
Function:
Adjustm ent of the frequency-dependent low ering of alter-
nator voltage (see 3.7.1 U nderspeed protection).
Direction of action:
Left-hand stop = beginning of reduction at >50/60 H z.
Right-hand stop = beginning of reduction only after
about > 30 H z.
In special cases, the underspeed protection can be
deactivated by m eans of sw itch S2.2 (see 9.2 Adjusting
elem ents).
This is necessary w hen regulating a D C voltage by w ay
of additional m odule U DC or in som e cases w hen using
external U F m odules.
Desired value:
R4
25-gang trim potentiom eter
Function:
Adjusting the alternator voltage (see 4.3 Desired value,
10.2 Desired value adjustm ent range).
Direction of action:
Left-hand stop = m inim um alternator voltage
Right-hand stop = m axim um alternator voltage
P component:
R1
1-gang trim potentiom eter
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 si-
gnals must not be used at these inputs.
27
Function:
Varying the proportional com ponent of the control cha-
racteristic.
Direction of action:
Anticlockw ise = sm all P com ponent
C lockw ise = large P com ponent
The recom m ended adjustm ent range show n in Fig. 8
P adjustm ent range m ust not be exceeded (see 10.3
Regulating param eters).
I component:
S1
16-stage code sw itch
Function:
Varying the I com ponent in the regulating characteristic
(see 10.3 Regulating param eters).
Direction of action:
Left (1 <- F) = sm all I com ponent
Right (1 -> F) = large I com ponent
Droop:
R7
1-gang trim potentiom eter
Function:
Adjustm ent 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 m ust be interchanged.
Droop matching:
R6
25-gang trim potentiom eter
Function:
M atching the various alternator nom inal currents and
current transform er ratios to the droop m onitoring system .
Direction of action:
Left-hand stop = m axim um com pensation value
Right-hand stop = m inim um com pensation value
At nom inal alternator current, R6 should be used to carry
out trim m ing to 2.5 V AC at the m easuring points
M P-STATIK D RO O P. If the alternator load current is
less than the nom inal current, this m ay be trim m ed to a
proportional voltage value.
Code switch:
S2
4-pole dip sw itch
Function:
Switch FUNCTION ON OFF
S2.1 none ./. ./.
S2.2
Activation and
deactivation
of underspeed
protection
Active
N ot
active
S2.3
Reduction of
actual value
sm oothing
N om inal Reduced
S2.4
Increasing the
D -param eter
Increased N om inal
Required basic setting:
AvK DSG alternators up to size 62:
S2.1 = no function
S2.2 = O N (underspeed protection)
S2.3 = O N (actual value sm oothing)
S2.4 = O FF (D param eter)
AvK DIG , DSG 74 125 alternators
S2.1 = no function
S2.2 = O N (underspeed protection)
S2.3 = O N (actual value sm oothing)
S2.4 = O N (D param eter)
9.3 Displays
Underspeed protection:
H1
yellow 5 m m LED
Caution:
Switch position 0 is not permitted.
28
H 1 lights up w hen the desired value or low ering of alternator
voltage in the case of underfrequency is active (3.7.1 U nder-
speed protection)
10. Starting up the "COSIMAT N+"
10.1 Basic setting and visual check
Before start-up, the follow ing basic settings of the "C O SIM AT N +"
voltage regulator m ust be checked:
R3 right-hand stop position
R4 left-hand stop position
R1 central position
(in the case of D IG , D SG alternators, 1/4
rotation anticlockw ise from the central position)
S1 Pos. 4
(in the case of D IG , D SG alternators Pos. 6,
at 600/750 rpm Pos. 9)
S2 S2.1 = no function
S2.2 = O N
S2.3 = O N
S2.4 = O FF (O N in the case of D IG and DSG
alternators from size 74)
R7 C entral position
R6 Left-hand stop
After basic setting, the follow ing visual checks m ust be carried
out:
a) H ave the sensing voltage connections (U , V, W
90...250 / 250...500) been correctly selected?
b) Do the sensing voltage connections possess a clockw ise-
rotating field? (If rotation is anticlockw ise, interchange U
and W ).
c) Is the supply voltage correctly connected (2 x single-
phase U H 1/U H 2 and W H 1/W H 2; three-phase U H 1,
VH 1, W H 1)?
d) Is the excess current circuit breaker in the alternator
sw itched on?
e) Is the droop transform er installed in the V phase?
f) Is the k I phase position of the droop current transform er
correctly connected? (In the case of external installation,
check from the alternator to the regulator).
g) Is the field connected w ith the correct polarity?
10.2 Desired value setting range
O nce all the basic settings and visual checks have been
carried out, the alternator can be started up.
a) Run up alternator to nom inal speed.
b) Set external set-point potentiom eter to the central position.
c) Adjust nom inal voltage using R4.
d) The alternator voltage can be adjusted around its
nom inal value using the external set-point potentiom eter.
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 lim it), adjust R1 slow ly to the left.
b) If there is tem porarily a tendency tow ards w eakly
dam ped hunting in the event of load surges, adjust S1 one
or tw o positions to the right.
10.4 Underspeed protection
a) 50/60 H z alternators to 0.95 x fN .
b) In the case of 50/60 H z alternators, turn R3 slow ly in
the anticlockw ise direction starting from the right-hand stop
position until H 1 lights up. Then turn it slowly in the clock-
w ise direction until H 1 goes out.
c) Run the alternator up to nom inal speed.
10.5 Droop adjustment
a) Load the alternator w ith nom inal current. M easure the AC
voltage at the droop sensing points M P-STATIK-D RO O P.
Adjust to 2.5 V AC using potentiom eter 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 clockw ise starting from its central
position.
Note:
W here a num ber of alternators are run in parallel, the
droop device m ust be at the sam e setting in all the
"C O SIM AT 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
Recom m ended droop settings:
3 % Parallel to the m ains (If the m ains supply is not
stable, the setting m ay have to be increased).
2 % Parallel operation w ith identical alternators.
6 % Parallel operation w ith different alternators w hose
regulators do not have a linear droop.
1 % Parallel operation w ith different alternators w hich
also have "C O SIM AT N or N +" regulators.
11. Important notes
11.1 Protection concept for external mounting
of regulator
The follow ing protective m easures m ust be taken if the regu-
lator is installed externally in the sw itching station:
The sensing line U -V-W is to be laid using short-circuit-proof
cable (1.5 m m
2
) from the alternator term inal strip X2 to the
sw itching station. AvK recom m ends the installation of a
three-phase circuit breaker w ith a therm al tripping current of
approxim ately 0.5 A. If this circuit breaker is tripped, the
alternator m ust be de-excited and stopped im m ediately.
If the regulator is installed externally, the connecting leads for
the external set-point potentiom eter, the droop current transfor-
m er, the droop sw itch and the I1/K1 exciter line are to be
provided w ith separate shielding. The shields m ust be earthed
at one end on the "C O SIM AT N +".
Protection concept:
The exciter system should be protected from excessive exciter
currents and voltages by a field discharge sw itch or relay.
This sw itch or relay should be connected as show n in the
relevant order-specific circuit diagram . The tripping criteria
w ill be determ ined by the protection required by the alterna-
tor.
W here the alternator is operated in stand-alone m ode, an
overvoltage protection system m ust be installed in the sw it-
ching station. In the case of operation in parallel w ith the
m ains or other alternators, an overcurrent protection system is
to be added.
DSG/ DIG alternators with auxiliary windings:
DSG and DIG alternators w ith auxiliary w indings are fitted
w ith an excess-current circuit breaker F1. This protects the
auxiliary w indings from excessively high therm al loading e.g.
as the result of an external short circuit involving the auxiliary
exciter voltage U H 1-U H 2 or W H 1-W H 2.
11.2 Mounting the regulator
The "C O SIM AT N +" m ust be m ounted w ith its longitudinal
axis vertical in case of convectional cooling to allow the air
to flow freely through its pow er stage. N ote the installation
position m arking U N TEN (= BO TTO M ) (connecting
leads tow ards the pow er stage). At fan cooling, the longitu-
dinal axis of the "C O SIM AT N +" has to be in air flow
direction. Deviating m ounting is only suitable after checking
by AvK.
There m ust be a 3 cm clearance all the w ay round betw een
the "C O SIM AT N +" and any structural elem ents that m ight
hinder flow (cable ducts, plates). This rule does not apply to
laterally m ounted additional m odules.
11.3 Excitation build-up
At the nom inal speed, the auxiliary excitation w indings on
DSG and DIG alternators m ust produce a rem anent voltage
of at least 10 V AC in order to ensure a satisfactory excitation
build-up.
H ow ever, problem s w ith excitation build-up m ay also be
caused by dirty de-excitation contacts or a field connection
of incorrect polarity.
In the case of alternators w hich have been stationary for a
prolonged period, it m ay 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 term inal to I1 and by its
negative term inal to K1 at nom inal speed. In the case of
tw o-phase auxiliary excitation m achines, the battery should
be connected to I2(PO SITIVE)/K2(N EG ATIVE).
11.4 Code switch S2
For standard applications of the "C O SIM AT N +", the follow ing
basic settings m ust be m ade before start-up at code sw itch S2
(see 9.2 Adjusting elem ents):
AvK DSG alternators up to size 62
S2.1 = no function
S2.2 = O N (underspeed protection)
S2.3 = O N (actual value sm oothing)
S2.4 = O FF (D param eter)
AvK DIG and DSG 74 125 alternators:
S2.1 = no function
S2.2 = O N (underspeed protection)
S2.3 = O N (actual value sm oothing)
S2.4 = O N (D param eter)
Any differences from these settings m ust be agreed w ith the
m anufacturer beforehand and taken into account in the w ay
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 "C O SIM AT N +" are
short-circuited (see 8. D iagram s of connections).
The lead betw een the droop sw itch and the regulator m ust be
screened.
The screen m ust be earthed at one end on the "C O SIM AT N +".
11.6 Changing the direction of rotation
To enable the droop sensing system to exercise the correct
effect, the "C O SIM AT N +" requires a clockw ise-rotating field
at its m easuring voltage connections.
Note:
The desired direction of rotation should be specified
w hen ordering the alternator. This is im portant w ith
regard to ventilation.
11.7 Synchronous motors
Synchronous m otors operate in a sim ilar w ay to synchronous
alternators in parallel operation. The direction of the active
pow er is rotated through 180 relative to the alternator (see
Figure 36 O peration of the synchronous m achine).
Starting from cos phi = 1, this has the follow ing im plications
for the reactive pow er:
G G iven a rising exciter current (overexcitation), the synchro-
nous m achine becom es a source of reactive pow er.
G G iven a falling exciter current (underexcitation), the synchro-
nous m achine becom es an acceptor of reactive pow er.
W hen used as a generator, the synchronous m achine is taken
as the reference point; w here it is used as a m otor, the m ains
are taken as the reference point.
W hen used as a generator, the synchronous m achine supplies
inductivereactive pow er to the m ains w hen overexcited.
W hen used as a m otor, the synchronous m achine draw s
inductivereactive pow er from the m ains w hen underexcited.
The droop system in the "C O SIM AT N +" operates w ith the
correct direction of action w hether the m achine is being
operated as a m otor or a generator. The direction in w hich
it is installed in the synchronous m achine and the w ay the
droop current transform er is connected to the "C O SIM AT N +"
rem ains the sam e (see 8. Diagram s of connections).
For m otor control, a cos phi controller (C O S m odule) is
required additionally.
Figure 36 M odes of operation of a synchronous m achine
11.8 Protective fuses
W hen the protective fuses are tripped, they m ust be replaced
w ith fuses of the sam e type.
Fuse type:
10 A super quick-acting IEC G 144.400
Tw o spare fuses are m ounted on the underside of the "C O SI-
M AT N +" (see 7. Dim ensions).
11.9 Drying out the alternator
If, because of inadequate insulation resistance, the alternator
has to be dried out at nom inal current by the short-circuit
m ethod, the "C O SIM AT N +" should be disconnected from
the supply and exciter field connections.
The alternator is dried out by applying an external source of
excitation.
Further inform ation on how to dry out the alternator can be
found in the alternator instructions.
Caution:
The power stage may be permanently da-
maged 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, in-
terchange 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,
externalsource (e.g. the m ains), the supply m ust not be
sw itched on until the alternator has started up.
W hen shutting dow n the alternator, the supply m ust be
sw itched off before the m achine com es to a halt.
The sw itch-on and sw itch-off point of the supply should be set
to 0.95 x fN using a frequency relay (BF1).
The double term inals at connections U H 1 and W H 1 can be
used to sw itch the supply on and off (see 8.5 De-excitation
circuit).
11.11 400 Hz alternator/ converter
O n 400 H z alternators < 100 kVA (as single m achines or
converters), sw itch S2.3 m ust be set to the "O FF" position.
11.12 Checking the insulation voltage of the
electric machine
Before checking the insulation voltage of the electric m achine,
the follow ing connections of the "C O SIM AT N +" m ust be
disconnected:
M easuring voltage U , V, W
Supply U H 1-U H 2, W H 1-W H 2
Exciter field I1-K1
The supply and m easurem ent connections of additional regu-
lator com ponents m ust also be disconnected.
All disconnected or interrupted connections should be isolated
in the appropriate m anner.
11.13 Exchange/ replacement; "COSIMAT N/ N3"
by "COSIMAT N+"
O n AvK alternators of series D SG , D ID BN , D ID BH and D IG ,
sizes ...74-86-99-114-125, sw itch S2.4 on the "C O SIM AT
N +" should be sw itched to the O N position. Sw itches S2.2
and S2.3 should be sw itched to the O N position. Sw itch
S2.1 should be set to the O FFposition.
The sequence of term inals W H 1 and W H 1has been
reversed on the "C O SIM AT N +". The connecting cable W H 1
m ust be connected to the correspondingly nam ed connecting
term inal of the "C O SIM AT 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 can-
not be adjusted w ith the set-point po-
tentiom eter.
Alternator voltage is too high.
Alternator voltage is too high and can-
not be adjusted w ith the set-point po-
tentiom eter.
Severe voltage dip upon loading.
Alternator does not respond to excitati-
on.
Cause
Input speed too low .
M easuring leads incorrectly con-
nected.
Set-point potentiom eter or its con-
necting leads are disconnected/inter-
rupted.
Broken m easuring lead.
M easuring leads incorrectly con-
nected.
Set-point potentiom eter or its con-
necting 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 sw itch has tripped.
Remedy
C heck w hether LED H 1 on regulator
lights up. If so, underspeed protection
device has been activated, run up al-
ternator to nom inal speed.
C heck m easuring-lead connections U ,
V, W on the regulator. C heck w hether
the nom inal voltage of the alternator is
w ithin the voltage range indicated on
the "C O SIM AT N +".
C heck set-point potentiom eter or its
connecting leads. Rectify fault.
Rectify fault.
C heck m easuring lead connections U ,
V, W on the regulator. C heck w hether
the nom inal voltage of the alternator is
w ithin the voltage range indicated on
the "C O SIM AT N +".
C heck set-point potentiom eter for short
circuit. C hange potentiom eter. C heck
set-point leads for short circuits. Elim ina-
te short circuit.
C heck regulator of driving m achine.
C heck protection fuse on the regulator
and exchange if necessary.
C heck rotating diodes V1 and surge
voltage protector V3 and R11 and
exchange if necessary.
C heck the speed regulator of the input
m achine. C heck the pow er transm issi-
on to the alternator.
Sw itch on the protective sw itch again.
If it trips once m ore, search for the fault
and repair it.
11.14 Malfunctions, causes and remedies
33
Malfunction
Alternator does not respond to excitati-
on.

Periodic fluctuations in the alternator
voltage w hen operated singly (stability
lim it)!
Cause
Rem anence too low .
DSG , DIG alternators:
Interruption in the auxiliary exciter w in-
dings.
DIG alternators (U N 11,5kV):
Interruption in the auxiliary exciter
m achine w indings.
DSG , DIG alternators:
Interruption in exciter w indings I1/K1.
DIG alternators (U N > 11.5 kV):
Interruption in exciter w indings I1/K1
and/or I2/K2.
Fault in regulator.
Fault in the regulator connections.
Regulator defective.
Rotating diodes defective.
Incorrect regulator setting.
Remedy
Alternator w ith auxiliary w inding:
Briefly connect positive term inal of 4.5
or 6 V battery to I1 and negative
term inal to K1 (at nom inal speed).
A lternator w ith tw o-phase auxiliary
exciter m achine:
Briefly connect positive term inal of 4.5
or 6 V battery to I2 and negative
term inal to K2 (at nom inal speed).
With alternator standing still!
C heck w indings U H 1 / U H 2 and
W H 1/W H 2 for interruptions using an
ohm m eter. Elim inate faults.
With alternator standing still!
C heck w indings W H 1/ W H 2 and
U H 2 / U H 1 / U H 3 for interruptions
using an ohm m eter. Elim inate faults.
With alternator standing still!
C heck w indings I1/K1 for interruptions
using an ohm m eter. Elim inate faults.
With alternator standing still!
C heck w indings I1/K1 and I2/K2 for
interruptions using an ohm m eter. Elim i-
nate faults.
C heck protective fuses and exchange
if necessary. Is the regulator receiving
excitation release and are the bridges
present at the double term inals I1/I1,
K1/K1, UH 1/UH 1and W H 1/W H 1?
C heck and elim inate fault.
C heck all regulator connections, input
and output leads. Elim inate faults.
Exchange regulator.
C heck rotating diodes V1 and voltage
surge protector V3 and R11 and
exchange if necessary.
Adjust R1 carefully in the anticlockw ise
direction and turn S1 one or tw o steps
to the right.
34
Malfunction
Alternator voltage fluctuates at irregular
intervals.
Reactive pow er output too high in par-
allel operation.
Reactive pow er output too low in par-
allel operation.
Active load not equally distributed.
Cause
Tem porary interruption in one of the
regulator supply leads.
M echanical regulator of the driving
m achine is sticking.
Droop set too low .
Transform er connections k/ I have
been bridged by the droop sw itch.
Phase angle connection (k/I) of the
droop current transform er has been
w rongly positioned.
Droop sw itch is not in alternator phase
V.
M easuring voltage connections U , V,
W w rongly positioned.
Droop set too high.
M easuring voltage connections U , V,
W w rongly positioned
This is affected by the driving m achine
only.
The "C O SIM AT N +" affects only the
reactive pow er.
Remedy
C heck connecting leads to the regula-
tor. C heck connections at the term inal
board of the alternator. Tighten all con-
tact screw s and nuts.
C heck speed regulator of the driving
m achine. Elim inate fault.
Adjust R7 slightly in the clockw ise di-
rection on the "C O SIM AT N +".
O pen bridge.
C heck connecting leads from the alter-
nator to the regulator. Interchange k/I
if necessary. The w hite secondary con-
nection of the droop current transform er
is k.
Install droop transform er in phase V.
C heck the sensing lead. "C O SIM AT
N +" requires a clockw ise-rotating field.
Interchange U and W if necessary (in
the case of anticlockw ise rotation).
Adjust R7 slightly in the anticlockw ise
direction on the "C O SIM AT N +".
C heck the sensing lead. "C O SIM AT
N +" requires a clockw ise-rotating field.
Interchange U and W if necessary (in
the case of anticlockw ise rotation).
C heck the drive m otor and its regulator.
We reserve the right to make technical changes.
35
12. List of figures
Figure 1 G eneral arrangem ent diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 2 Adjusting elem ents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 4 C haracteristic quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 5 Trend of the control property . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 6 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 7 Droop characteristic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 8 P adjustm ent range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 9 U nderspeed protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 10 Equivalent control circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 11 Additional m odule C O S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 12 Additional m odule Q PF A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 13 Additional m odule Q PF B . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 14 Additional m odule Q PF C . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 15 Additional m odule SB2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 16 Additional m odule TF1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 17 Additional m odule ES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 18 Additional m odule U F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 19 Additional m odule U F3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 20 Additional m odule SR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 21 Additional m odule EI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 22 Additional m odule U DC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 23 Additional m odule KP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 24 Additional m odule ER1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 25 Dim ensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 26 Internal m ounting, D SG alternators 52 74 . . . . . . . . . . . . . . . . . . . . 21
Figure 27 External m ounting, D SG alternators 52 74 . . . . . . . . . . . . . . . . . . . . 21
Figure 28 Internal m ounting, D SG alternators 86 125 . . . . . . . . . . . . . . . . . . . 22
Figure 29 External m ounting, D SG alternators 86 125 . . . . . . . . . . . . . . . . . . . 22
Figure 30 Internal m ounting, DIG m edium -voltage alternators w ith U N 11.5 kV . . . . . . . . 23
Figure 31 External m ounting, DIG m edium -voltage alternators w ith U N 11.5 kV . . . . . . . . 23
Figure 32 Internal m ounting, DIG m edium -voltage alternators w ith U N > 11.5 kV . . . . . . . . 24
Figure 33 External m ounting, DIG m edium -voltage alternators w ith U N > 11.5 kV . . . . . . . . 24
Figure 34 De-excitation circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 35 Field current/field voltage m onitoring . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 36 M odes of operation of a synchronous m achine . . . . . . . . . . . . . . . . . . . 31
36
AvK Deutschland GmbH & Co. KG
Niederlassung Dreieich
Benzstrae 47 - 49
D - 63303 Dreieich
Telefon: ISDN 0 61 03/50 39 - 0
Telefax: 0 61 02/50 39 - 40
e-m ail: infoavkdr@ new age-avkseg.com
http://w w w .new age-avkseg.com
AvK Deutschland GmbH & Co. KG
Bunsenstrae 17
D - 85053 Ingolstadt
Telefon: 08 41/7 92 - 0
Telefax: 08 41/7 92 - 2 50
e-m ail: infoavkin@ new age-avkseg.com
http://w w w .new age-avkseg.com
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