Generator For Wind Turbine: Installation and Maintenance Manual

4736 en 07.
2011 / b

GENERATOR FOR WIND TURBINE

Installation and maintenance manual
LEROY-SOMER INSTALLATION AND MAINTENANCE MANUAL 4736en-2011.07/b
GENERIC
Wind Turbine Generator

2

MODIFICATIONS FOLLOW-UP
Date Ind. List of modifications between revisions
2011.06 a Creation
2011.07 b Water-jacket fill up procedure

LS APPROVAL
Date:

Name:

Function:

Signature:

SAFETY MEASURES
Before using your generator for the first time, it is important
to read the whole of this installation and maintenance
manual.
All necessary operations and interventions on this
generator must be performed by a qualified technician.

Our technical support service will be pleased to provide any
additional information you may require.

The various operations described in this manual are
accompanied by recommendations or symbols to alert the
user to potential risks of accidents. It is vital that you
understand and take notice of the following warning
symbols.

Warning symbol for an operation capable of damaging or
destroying the generator or surrounding equipment

Warning symbol for general danger to personnel.

Warning symbol for electrical danger to personnel.

Note: is remark to the end user

Note: LER0Y-S0NER ieseives the iight to mouify the
chaiacteiistics of its piouucts at any time in oiuei to
incoipoiate the latest technological uevelopments. The
infoimation containeu in this uocument may theiefoie be
changeu without notice.
TABLE OF CONTENTS
1 GENERALS...................................................... 3
1.1 TYPE DESIGNATION..................................... 3
1.2 IDENTIFICATION.......................................... 3
1.3 HIGH ALTITUDE UTILISATION ....................... 3
1.4 TIGHTENING TORQUE TABLE........................ 3
1.5 TRIP & ALARM SETTINGS............................. 4
2 TRANSPORT AND STORAGE........................ 4
2.1 PRECAUTIONS FOR TRANSPORT .................. 4
2.2 MARITIME PACKAGING................................. 4
2.3 STORAGE WAREHOUSE............................... 4
2.4 LONG TERM STORAGE OR STAND STILL......... 4
2.5 STORAGE OF A MACHINE............................. 4
3 COMMISSIONING............................................ 4
3.1 HOISTING AND POSITIONING........................ 5
3.2 SLIPRINGS AND BRUSHES............................ 5
3.3 FILL-UP THE WATER-JACKET........................ 5
3.4 CHECKING THE INSULATION......................... 5
3.5 EARTHING.................................................. 5
3.6 COUPLING AND ALIGNMENT ......................... 6
3.7 ACCESSORIES............................................ 7
3.8 PROTECTIONS............................................ 8
4 MAINTENANCE............................................... 8
4.1 BEARING ARRANGEMENT & LUBRICATION ..... 8
4.2 SLIPRING AND BRUSHES.............................. 8
4.3 SPACE HEATERS ...................................... 10
4.4 CHECK AND MAINTENANCE PLAN............... 10
5 SPARE PARTS.............................................. 10
6 GLOSSARY.................................................... 11
7 DECLARATION OF INCORPORATION........ 13
8 COMMISSIONING CHECKS LIST................. 14

GENERIC

3
1 GENERALS
1.1 Type designation
Leroy Somer Wind Turbine Generators type designation is
defined as follows:
G53 WJ75 / 4P
G= Asynchronous
A = Synchronous
P = Permanent magnets
53 = Frame size

Cooling technology
WJ = Water Jacket

4P = 4 poles

The designations used in these instructions are to be
understood as follows:
DE = Drive End
NDE = Non- Drive End
Direction of rotation is always given looking onto the DE
1.2 Identification
Generator nameplate
Direction of rotation is indicated on the frame near the DE
bracket
Cooling fluid: water-glycol

Type: refer to 1.1
Type designation
N: generator serial
number
Power: Nominal
power (in KW)
Cos Phi: Power
factor range
Voltage: Rated
stator supply voltage
(in V)
PH: Number of
phases and electrical
coupling
Current: Rated
current (in A)
Overspeed: Max
mechanical
overspeed (the
generator has been
validated for 2mn at
this speed) (in rpm)

Speed: Speed
range during grid
operation (in rpm)
IP: ingress protection Temperature rise
/ Stator and rotor
insulation class
Freq: Frequency (in
Hz)
Duty: Service factor
(S1: continuous
operation)

Rotor
Weight (in kg) Water temp: Max
Temperature of the
fluid circulating into
the stator (in C)
Urt0: locked rotor
voltage (in V)
Date: manufacturing
date
Amb: Max
temperature around
the generator (in
operation) (in C)
Irt: Max rotor
current (in A)
Grease type:
DE side: bearing type
NDE side: bearing type
Grease quantity: refer to your
machine specific technical
documentation
1.3 High Altitude Utilisation
For Altitude above 1000 meters ( 3 300 feet), an increase
of rotor temperature rise is normal. Then we have to de-
rate the power of 1% by step of 100 meters ( 330 feet).
Example: for an altitude of 1800m, de-rate the power by
(1800-1000)/100= 8% (Standard IEC 60034-1)
1.4 Tightening torque table
During spare part replacement, a maximum torque must be
applied while tightening or loosening screws.
If no specific torque specified, please use the table below.
The table below shows the tightening torques to apply for
class 8-8 screws:

Nominal
(mm)
Tightening
Torque (mN)
Nominal
(mm)
Tightening
Torque (mN)
3 1,16 18 261
4 2,66 20 370
5 5,2 22 509
6 9,1 24 637
8 22 27 944
10 44 30 1 280
12 76 33 1 739
14 121 36 2 232
16 189 39 2 900

GENERIC

4
1.5 Trip & alarm settings
Recommended values for F temperature rise are as follow:
Alarm Trip
Stator PT100 145C 155C
Bearings PT100 90C 95C
2 TRANSPORT AND STORAGE
We advise you to proceed to a general inspection when
receiving your generator at its final destination for any
potential transport damage. If there is any damage, send
a registered letter to the Transport Company with a copy
of the receipt signed by incoming department and truck
driver. The receipt shall mention the damages to the
generator. Send a copy of the record of damage to Leroy
Somer within 3 days after reception.
2.1 Precautions for transport
During transport, shocks level applied to the machine must
remain below 30 m/s.
The shaft locking system must be installed when the
machine is transported
Machine temperature must remain within the range -20C
to +50C.
The machine must be protected against bad weather
conditions and condensation.
The machine must not be handled at temperature below
-20C, for lifting the machine, please refer to section 3.1.
2.2 Maritime packaging
Generators are shipped in a seaworthy packing
hermetically sealed (Crate 4C SEI NIMP 15 Standard).
Breaking the hermetic protective film discharges Leroy
Somer of its warranty.
2.3 Storage warehouse
The machine must be stored in a clean and dry premise
and must not be subject to abrupt temperature changes or
to high humidity. Storage at an ambient temperature of +5
to +45 C is recommended.
The machine must not be subject to vibrations during
storage. In any case, generator must be stored empty of
cooling water.
2.4 Long term storage or stand still
Before stopping the machine for a long period (several
months), it is essential to take several precautionary
measures:
The space heaters must be switched on at all times (do not
forget to ground the machine).
For water-coolers, the water flow must be shut off. If the
water is not treated and if there is likelihood of freezing, the
exchanger must be drained.
2.5 Storage of a machine
If the generator is new there is no need to refill the bearing
cage with new grease. If the machine already ran for
several hundreds of hours, then the used grease must be
removed and replaced by new grease. To be sure that all
the used grease has been totally removed, 2 volumes
(refer to your specific installation and maintenance manual)
of new grease must be injected.
Once it is done, store the machine for 6 months. Then
every 6 months, turn the machine shaft line of few turns
and inject while rotating one grease volume per bearing
(refer to your specific installation and maintenance
manual).
It is mandatory to place a protective foil between sliprings
and brushes (earthing brush and main brushes)

The grease used for re-greasing must absolutely be the
one specified on the machine nameplate
Before starting the machine up again, it will be necessary
to carry out a start-up inspection:
- Check the insulation paragraph 3.3,
- Check the alignment paragraph 3.5.2.3,
- Check the filters paragraph 3.6.3,
- Check the protections paragraph 3.7,
- Test that the centralized lubrication system is working
properly.
Note: a commissioning check list available at the end of
the document
3 COMMISSIONING

Generators are industrial products. Therefore, they must be
installed by qualified experienced personnel. Leroy Somer
will not assume any legal responsibility in case of non
observation of this installation and maintenance manual.

Note: a commissioning check list available at the end of
the document
GENERIC

5
3.1 Hoisting and positioning
The generator is designed to be used with a maximum
inclination angle of 6 compared to a horizontal reference
(DE higher than NDE). In function of the terminal box
design and location, there are 2 or 4 lugs to lift the
machine.

Note: refer to the nameplate or to your machine specific
technical documentation for its weight
3.2 Sliprings and brushes
Remove the protective foil between sliprings and brushes
(needed for transport & storage periods). Brushes should
never come into contact with cleaning solvent, the solvent
vapor or oil.

Silicon products are totally prohibited in the sliprings
compartment.
3.3 Fill-up the water-jacket
When filling-up the water-jacket,
activate the bubble trap as follow:
1 - Turn anticlockwise for quick filling the cap (E)
2 - Set the cap in the original position after filling.

Do not remove the cap during operation.

3.4 Checking the insulation
Before starting the generator, it is necessary to check the
insulation resistance (IR) between phases and earth (on
stator & on rotor), and between phases (only for stator).
This measurement is carried out with a mega-ohmmeter
under a 500 volts D.C. (do not use a magneto electric
system).
First, carry out an initial test at 500 volts for 60 seconds
and:
If the IR value is higher than 10 mega-ohms,
insulation is correct, start allowed,
if the IR value is lower than 10 mega-ohm, dry the
concerned assembly in a drying oven at a
temperature 80C in order to reach an IR > 100
mega-ohms. Restart IR measurement when drying
is finished.
If the generator cannot be placed in a drying oven:
Connect the generator to a 3-phases A.C voltage
source reduced to approximately 10% of the rated
voltage (Un x 0.1) for 12 hours (use an induction
regulator or a reduction transformer with adjustable
outlets).
Nota: Check that the stator PT100 sensors
temperature remains below 100C
The A.C current will be monitored via a clamp-on
ammeter.
While drying, all generator orifices must be opened
(terminal box, drain holes).
3.5 Earthing
The generator must be earthed and conform to the current
European regulation. Earth terminals are located on
machine foot.

2 lugs
4 lugs

Earthing plug
GENERIC

6
3.6 Coupling and alignment
3.6.1 Preparation
Remove the rotor locking device

Turn the rotor by hand before connecting it, to detect any
possible fault due to handling

The end of the shaft is protected from corrosion.
Clean it before coupling.

3.6.2 Machine alignment
3.5.2.1 Alignment general points

Misalignment between the gear box shaft and the
generator shaft is a common cause of premature bearing
failure. Such misalignment may generate excessive
vibration and creates unacceptable stress for generator
bearings. The alignment must be done taking in
consideration the shaft movement correction
The alignment consists in obtaining the driving shaft and
the driven shaft coaxial when operating at nominal
conditions (machine rotating at its operating temperature).
The machine must be aligned according to the Leroy
Somer standard (paragraph 3.5.2.3) and adheres to the
manufacturer's alignment standard for the drive machine
and coupling.
The correct locating of the parts must be obtained by
inserting shims under the machine pads. The Anti friction-
bearing machines with a positioning bearing (standard
machine) do not have axial play. The machines are
delivered with the rotor mechanically centered (axially and
radially) in relation to the stator.
3.5.2.2 Two bearings machine alignment
Machines without axial end play
The alignment must take the tolerances of the coupling into
account. A misalignment, acceptable by the coupling, must
not create an excess load on the bearing subsequent to the
axial and radial stresses outside the tolerances of said
bearing.
To check the alignment, there are different methods: the
"double concentricity" method is described in the
"alignment procedure" subsection 3.5.2.3.
3.5.2.3 Alignment procedure
Checking "Double concentricity" alignment method:
This method is not sensitive
to axial movements (the
alignment methods using
axial measure may often be
perturbed by small axial
movement of the rotor). It is
possible to check the
alignment with the coupling
installed.

Equipment required:
- Two rigid brackets (Rigidity of the brackets is very
important).
- Two micrometers Implementation.
During the measures, both shafts must turn simultaneously
in the same direction. (For example: the coupling installed
with its screws loosened). By turning both shafts
simultaneously, the measurement isnt affected by the error
resulting from the two shaft ends run out.
Note: below interpretation of measurements are for
example
Measurements:
The "C1" and "C2" micrometers are located at an angular
difference of 180. The longer the distance "L" the better
should be the sensitivity to detect the angular error. The
reading should be performed 4 times for the "C1" and "C2"
micrometers: at 12h, 3h, 6h, 9h It is recommended to
record the results and draw the axes for better evaluation,
as explained below. Values given in millimeter. The reading
Rotor
locking device
Rotor
evice
GENERIC

7
is considered positive (+) when the micrometer stylus is
pushed inwards.
Measurements referring to the vertical plane:
Considering the vertical plane "C1": The vertical action
towards the top of shaft "A" on the micrometer is dominant.
In the plane "C1" the axis "A" is higher than axis "B (0.9-
1)/2 = - 0.05mm
In the vertical plane "C2", the vertical action towards the
top of shaft "B" on the micrometer is greater.
In the plane "C2" the axis "B" is higher than axis "A" (1.34
1.02)/2 = 0.16mm
The respective position of the axes is as drawn on right
drawing. Regarding the vertical plane the angular
alignment error is: (0.16+0.05)/400 = 0.0525mm/100mm (It
is not acceptable)
Measurements referring to the horizontal axis:
In the plane "C1" the axis "B" is further to the right than "A
(1.040.86)/2 = 0.09mm
In the plane "C2" the axis "B" is further to the left than "A
(0.701.64)/2 = - 0.47mm
The representation of the shafts is as drawn on above
drawing.
Regarding the horizontal plane the angular error is:
(47+9)/400 = 0.14mm/100mm (not acceptable)
In the both planes the parallelism error is:
or
(It is not acceptable)

Alignment limits are strongly linked to coupling type (semi-
elastic, elastic, rigid). As semi-elastic couplings have a
stiffness that varies a lot from one to another, alignment
tolerances are given for a rigid coupling.
Shaft alignment limits are:

3.7 Accessories
3.7.1 Lubrication unit

To lubricate the bearings (DE & NDE), your generator may
be equipped with a centralized lubrication system. If so,
refer to your specific installation and maintenance manual
to have more information.
In any case, never lubricate the bearings (with the
centralized lubrication system or with a manual pump)
while machine is not rotating.
3.7.2 Encoder
Your generator may be
equipped with an optical
encoder. If so, refer to
your specific installation
and maintenance manual
to have more information.

Note: the half-pipe protection over the encoder is to
protect it from accidental shocks. Do not step on it.
3.7.3 Filters
Sliprings compartment of induction generators may be
equipped with a G4 Class filter to trap carbon dust
generated by brushes wear. G4 filters are not washable.
Please refer to your specific installation and maintenance
manual for filter exchange.
0.01mm
100mm
Angular error
0.02mm
Parallelism error
GENERIC

8
3.8 Protections
3.8.1 Surge arrestor
Your generator may be equipped with surge arrestor
systems to protect the stator and/or rotor.

The surge arrestor system is composed of:
1 surge arrestor (made of 3 varistors and 1
spark gap)
3 fuses
1 tri-polar fuses holder
For details, see spare parts list
3.8.2 Protections testing
All the protections should be tested before commissioning:
contact-breakers
ground connection
overcurrent
overvoltage
4 MAINTENANCE
4.1 Bearing arrangement & lubrication
The bearings must be regularly re-greased. The daily
grease quantity per bearing is given in the table in your
specific installation and maintenance manual.

Please refer to your specific installation & maintenance
manual for the maximum bearings temperature
RECOMMENDATIONS
When you detect on the generator an abnormal/ unusual noise
or vibration or an abnormal heating of the bearing when it is
correctly greased, then state of bearings must be checked.
The grease used for re-greasing must absolutely be the one
indicated on the name plate of your generator.
Do not introduce any object into the grease drain plug to avoid
any kind of pollution in the bearing compartment. Dirt is
deadly. When working with bearings, make sure that the
workplace is as clean as possible. Even tiny particles of dirt or
grit entering a bearing will damage the bearing internally and
inevitably shorten its operating life.
Damaged bearings must be replaced as soon as possible
to prevent worse damage to the generator and to the driving
equipment.
Always be sure to check the contact surface for the seal lip. It
must be in good condition. Even the smallest mark or rust will
damage the seal lip and allow water penetration and eventual
corrosion
Never use a hammer to hit directly on the bearing or shaft
4.2 Slipring and brushes
If your generator is
an induction type, it is
equipped with a
slipring surrounded
by a brush holder.
The brush holder is
equipped with
brushes in contact
with the slipring
(Phase brushes and
ground brushes).
Brush dimensions
are: 100mm x 20mm
x 40mm

4.2.1 Sliprings, brushes and brush holder
cleaning method
Remove all brushes before beginning with the cleaning
work. Brushes, brush-holder and slipring are best cleaned
of carbon dust with a vacuum cleaner. Mechanical dry
cleaning should always be the preferred cleaning method.
Only vacuum cleaners with soft suction nozzles of rubber
or plastic should be used. Use a brush to wipe clean and
push the carbon dust towards the vacuum cleaner nozzle.
On the sliprings, the developed patina (refer to definition
below) must not be destroyed by unnecessary grinding or
hand stoning, not even when replacing the brushes, it
should stay completely untouched.

Brushes should never come into contact with cleaning
solvent, solvent vapor or oil. Silicon products are totally
prohibited in the sliprings compartment.
What is patina? Patina, or skin, which plays such an
important part in brush behaviour, must not be regarded as
static: it is something alive and constantly changing under
effects of opposing factors, some building it up and others
destroying it. Under the majority of given operating
conditions a dynamic equilibrium is reached when the skin
thinning and the skin recovery process balance.
The colour of the patina is largely an effect of thickness.
The patina appearance depends mostly upon the brush
grade in use and upon the brush electrical load.
Irregularities in the skin formation arise from electrical or
mechanical faults and can therefore be used in diagnosing
troubles. If the slipring temperature, brush temperature
and air humidity are correct, a patina will be built up
automatically.
4.2.2 Brush wear
Brush wear shall be around 2mm to 5mm per 1000 hours
with a 65% of relative humidity. In case of a hygrometry
below 30% of relative humidity, be aware that the brushes
could wear faster. Brushes must be changed as soon as
one brush length reaches 30mm (i.e. when 70% of total
length is worn). Please note that ground brushes wear a
little bit faster than power brushes.
GENERIC

9
Brush wear detectors will detect when one brush has
reached its signal length. It is mandatory to change all the
brushes when one is worn. The brush gear should be
blown out occasionally and the brushes must always slide
freely in their brush gear.

The max remaining length must always exceed 20mm
It is mandatory to change all brushes when one is worn
4.2.3 Brush change
4.2.3.1 Phase carbon brush 40 x 20
1.) Press spring clip P1 towards the carbon brush and pull
out upwards
2.) Loosen the M8 screws on the carrying ring and remove
loom
3.) Remove carbon brushes P3
4.) Clean carbon guides (attention: do not use pointy
instruments)
5.) Clean spring clip. We recommend rolling in the self-
recoiling spring and cleaning it with soft material.
(Attention the self-recoiling springs may not be rolled up
completely)
6.) Insert new carbon brushes P3, replace loom and
tighten screw M8 with a 22Nm torque.
7.) Insert spring clip P1 until both arresting protrusions
engage.
8.) Grind in carbon guides. (See paragraph 4.2.4 new
brushes grinding in).

4.2.3.2 Grounding carbon brush 40 x 20
1.) Press spring clip P1 towards the carbon brush and pull
out upwards
2.) Loosen the M8 screws P2, and remove loom
3.) Remove carbon brushes P3
4.) Clean carbon guides (attention: do not use pointy
instruments)
5.) Clean spring clip. We recommend rolling in the self-
recoiling spring and cleaning it with soft material.
(Attention the self-recoiling springs may not be rolled up
completely)
6.) Insert carbon brushes P3, replace loom and tighten
screw P2 M8 with 22 Nm.
7.) Insert spring clip P1 until both arresting protrusions
engage.
8.) Grind in carbon guides (See paragraph 4.2.4 new
brushes grinding in).

4.2.4 New brushes grinding in
This operation is to ensure that there is a good electric and
mechanical contact in axial and tangential direction
between sliprings and brushes.
Place an Emery cloth of grade 100 between slip rings and
brush, it should overlap in the direction of rotation and
then tape both ends together. Rotate the rotor by hand
until the tread of the brushes is uniform. It must be
ensured that the Emery cloth is moved along the slipring
so that the tread is not undefined.

Grinding is completed if the tread of the brush is uniform.
Important: After the brushes have been grinded, the
resulting dust must be removed carefully from the
slipring cavity. Safety regulations must be adhered
too.
After bedding, remove each brush from its holder and
carefully clean away all traces of carbon dust from the
slipring with a vacuum cleaner.

Upon improper grinding of the carbon brushes the
behaviour of the machine may be in danger.
Arcing due to the insufficient contact surface between slip
rings and brush causes melting on the slip rings tread.
The resulting craters on the entire slip rings tread cause
excessive brush wear and therefore increase amounts of
brush dust with the danger of:
Jamming the brushes in the holder
Reducing the insulating resistance
Electrical flashovers in the slipring cavity
WRONG
GENERIC

10

After grinding in and cleaning, test for brush rigid and
slipring unit:
Voltage 1000 VDC
If the insulation is below 1 Megohm please clean the rigid
once and make the test again. The electric test shall be
done with 250 VDC, 500 VDC and further with 1000 VDC.
If the insulation value is below 1 Megohm with 500 VDC
please check up the rigid and clean the rigid once more. If
the surface does have a patina never remove it.
4.3 Space heaters
- Induction generators: there are space heaters in 2
places: inside the generator, mounted on the NDE bracket
and inside the slipring unit compartment against the
supporting wall.
- Synchronous generators: there are space heaters only in
one place: inside the generator, mounted on the NDE
bracket.
4.4 Check and Maintenance plan
5 SPARE PARTS
Spare parts can be ordered by contacting the following
department:
Moteurs Leroy Somer
Spare parts department
45800 Saint Jean de Braye
FRANCE
[email protected]
Tel: 00 33 2 38 60 42 80
Operation

Period
/ frequency
Alert
/ criteria
Check that the fixing screws of the
generator are tightened
First 1500 RH
(***)
N.A.
Check that the connection cables
are tightened
First 1500 RH
(***)
N.A.
Check slipring condition (brush
wear, slipring patina, abnormal
carbon dust presence (if so then
replace filter)
First 1500 RH
(***)
Brush wear
exceeds 10mm
Check slipring condition (brush
wear, slipring patina, abnormal
carbon dust presence)
Biannual No patina on
the sliprings
Clean the brushes (ground and
excitation), slipring and brush
holder
Biannual N.A.
Check brushes wear (ground and
excitation) (**)
! Wear difference from brush to
brush shall not exceed 5mm !
Biannual Brush wear
exceeds 6mm
/1000 RH (***)
Sliprings dimensions check Every 5 years N.A.
Manual grease injection (*) Biannual
Centralized lubrication unit refill Biannual Grease level
didnt change
since last check
Electrical protections check
Surge arrestor and fuses
Biannual Out of order
For synchronous generator, check
the varistors and diodes
Annual Large current
pass in reverse
direction
Circuit open in
both direction
Empty the used grease boxes Biannual Grease/oil not
present
Replace filters Biannual N.A.
Activate the bubble trap device Biannual No more gas in
circuit
Check vibration (high and low
frequency)
Note: regularly scheduled readings
provide a historical perspective on
generator bearings wear
Biannual
Check visually any liquids
leakages (grease and cooling
liquid)
Biannual Leakages
Check the rotor and stator
insulation resistance and the
polarization index
Yearly 1MOhm
500VDC 60
seconds
(*) volume to be injected: refer to your generator specific installation &
maintenance manual
warning: generator must be in rotation of at least 100rpm while injecting
grease
(**) Determine wear rate in mm per 1000 hours of operation and compare
with earlier figures to obtain information on the functioning of the sliprings
and brushes.
(***) Generator Running Hours

These two brushes
on the left are well
resurfaced.
This brush isnt
grinded in
enough.
The area in the
triangle has not
been resurfaced
enough during
grinding in.
GENERIC

11
6 GLOSSARY

General

DE
NDE NDE
General
DE
Used grease box
Slipring compartment
Air filter
Encoder
Slipring compartment
air inlet
Lifting lugs
Auxiliary terminal box
Stator terminal box
Centralized lubrication
system
Generator frame
Auxiliary terminal box
Cooling liquid tube for
the water jacket
External bearing cover
Stator terminal box
DE Bracket
Grease drain plug
Used grease box
External bearing cover
Lifting lugs
GENERIC

12
Slipring unit (Induction generators)

Diode bridge (Synchronous generators)

Synchronous generators)
Space
heater
Structure
rod
Slipring
cooling fan
Brush gear
Slipring
Rotor
phase
connection
Brushes
Brush
spring
2 Ground
brushes
Ground
bounding
wire
Diode
Diodes heat sinks
Encoder wheel
Rotor coil wires behind
Diode
Varistor
GENERIC

13
7 DECLARATION OF INCORPORATION

GENERIC

14
8 COMMISSIONING CHECKS LIST

GENERAL PRESENTATION:
This procedure is intended for use as a guide for the on-site commissioning of the generator. Such work
is to be performed by skilled and experienced people in the start-up of this type of equipment.
it should be noted that this section covers procedures related only to the generator equipment provided
by LEROY SOMER Orlans and its subcontractors. Its likely that, in parallel to the procedure, other
equipment in the powerhouse or project would also need to be commissioned for proper installation and
operation. Procedures for checking such equipment and systems have not been included and should be
provided by others.
The people in charge of the commissioning should be completely familiar with the equipment, the
following procedures and the electrical control.

NEGLECTING TO FOLLOW THIS PROCEDURE COULD RESULT IN IMPROPER UNIT
PERFORMANCE AND/OR JEOPARDIZE PLANT OR PERSONNEL SAFETY.
We advise you to examine the safety instructions in the
generator instruction book delivered with the generator

GENERATOR DATAS

TYPE FREQUENCY HZ
SERIAL N SPEED RPM
VOLTAGE V OUTPUT KVA
Synchronous POWER FACTOR
Asynchronous RUNNING HOURS
Cooling system SITE NAME
GENERIC

15
1 GENERAL CHECKS
OK
The machine is installed in accordance with the usual recommendation and guidelines given in Leroy Somer
instruction book installation and maintenance manual

Alignment values (angle; concentricity) to be reported by customer (attached the report)
Confirm that all plant is clean and free of all debris or other objects (grits, rafters, tools, etc).
Check if there are any shocks marks on the generator
Shaft hand rotation is possible
If there is a slipring compartment, check that protective foils between slipring and brushes have been removed
Auto lubrication system is properly working:
- Check Sequences set up
- Check that lubrication system is working when activated through PLC

Alarms & Protection:
- Check if worn brushes detection is properly working
- Check that all the generator protections of the nacelle are activated and list it
- Check surge arrestors default detection is properly working

Brushes are properly installed on slipring unit
Space heater is properly connected and activated
Air inlet and outlets of the generator are free from any obstacles
Water lines are connected to the generator cooler or frame (check for any water leakage)
After filling-up the water circuit, please open the bubble trap device. Close it after an hour
Any additional part out of LS scope of supply are assembled on the generator
2 ELECTRICAL CHECKS
2.1 Electrical connections:
OK
Check the auxiliary wiring between generator and control panel (ie: temperature sensors, space heaters, ) as per
schematics installation and maintenance manual

CARRY OUT INSULATION RESISTANCE MEASUREMENT ON STATOR
(Refer to installation and maintenance manual for the method and voltage to be applied). If cables are connected,
and 1 problem is met, disconnect cables and restart the test.

Measurement device: ..Ambient temperature:
windings Volts time (M) Comments
stator
3 ph and ground
U1 ; V1
V1 ; W1
U1 ; W1
Reconnect all the wires at the stator cables if it was necessary to dismount it.
Check visual aspect inside the terminal box (no tools etc.. left inside)
Measure the IR at the rotating rectifier for the exciter rotor and main rotor (refer to instruction book for the
method and voltage to be applied)
Rotor & ground
Exciter (synchronous
generator only)

Armature (rotor exciter
of synchronous
generator only)

Check all the connections, input/output contact from/to PLC
2.2 PT 100 sensors:
PT 100 sensors reading (stator + bearing + Air & water etc)

Alarm & Trip setting.

GENERIC

16
3 RUNNING TEST (MANUAL OPERATION)
3.1 No load test:
Comments
Start up the cooling water system motor pump and check main cooler water flow.
Pressure: bars Water flow Cm/h Inlet C

Start the unit without excitation gradually from 0 to rated speed
Control rotation of the generator
Listen for any abnormal or strange sounds which may indicate problem areas; in such case stop immediately
the generator

Measure the vibration overall rms (mm/s); bandwidth: 5hz to 1000hz
at DE & NDE bearings in the 3 direction (axial, horizontal, vertical)

DEV DEH DEA NDEV NDEH NDEA

Measure the bearings temperature C at DE&NDE up to stabilisation
Time DE THRUST DE CTHRUST DE RADIAL NDE RADIAL

Stop the rotation and check the break (if break is provided)
Start the unit and run it to nominal speed with excitation off, and check if residual voltage are balanced
between 3 phases :

Switch on the excitation (synchronous generator only)
Following data to be measured and reported
U1 V1 W1 Iexcit Temp Winding Temp DE Temp NDE

Phase rotation control
Vibration level (mm/s); in 3 directions DE/NDE (axial, horizontal, vertical)
DEV DEH DEA NDEV NDEH NDEA

Delta & Star connection control
Inject grease at low rpm (20% of your bearing grease volume (*))

(*) Refer to your generator specific installation and maintenance manual

3.2 Emergency stop: (if requested by the customer)

Refer to Turbine manufacturer instruction to obtain the runaway speed
During over speed, survey the bearing temperature and vibration
After over speed, control vibration behaviour
Check if emergency stop is properly working

GENERIC

17
3.3 On load test:
Before starting the load tests, check phases sequence and synchronization sequence (Out of Leroy Somer scope)
Check if there are any abnormal over-current phenomenon during grid connection
Adjust the Power Factor if required (within Leroy Somer specification)
Take the load gradually from 0 to 100% by steps of 25%
Record for each steps:
- Electrical output (KW)
- Power Factor
- Voltage (V)
- Current (A)
Time DE
temp
NDE
Temp
Water
Inlet temp
Water
outlet temp
Phase U
Temp
Phase V
Temp
Phase W
Temp

- Bearing vibrations in global RMS _ velocity in mm/s (5-1000Hz)
If possible measure also acceleration in g (10-10000 hz)
DE-V DE-H DE-A NDE-V NDE-H NDE- A

-
time kw pf volts I stator I exc
I rotor
U1C
(*)
V1C
(*)
W1C
(*)

(*) get the curves from the PLC when possible
- Compare all data with factory test report.

4 DRAWING & SCHEMATICS

Outline drawing: EN rev.
Main rotor drawings: P1 .rev.
Schematics: S4 .rev. (Folio 1 to )
5 CONCLUSIONS
- Excitation Current/voltage
- Winding temperature
- Bearings temperature

LEROY SOMER EPG 16015 ANGOUEME CEDEX FRANCE
338 567 258 RCS ANGOULEME
S.A. au capital de 62 779 000
www.leroy-somer.com

Generator For Wind Turbine: Installation and Maintenance Manual

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Generator For Wind Turbine: Installation and Maintenance Manual

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4736 en 07.

LEROY-SOMER INSTALLATION AND MAINTENANCE MANUAL 4736en-2011.07/b

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