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TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
Information is given for guidance only. We do not accept any responsibility for the manner in
which the information is used, nor the consequences thereof.
The design and manufacture of equipment is subject to constant review and as a result the
information provided herein may vary from that manufactured.
Verbal or written modifications to the information contained herein have no legal status unless
confirmed in writing by the Technical Director or his nominated deputy.
The manual, and any amendments, should be maintained for the lifetime of the equipment.
The manual is written as a 'stand-alone' document, but should be read in conjunction with any
referenced or associated documentation.
All pages and topic headings are numbered for easy reference. Cross-reference(s) to associated
paragraphs and documentation is included where appropriate. When referencing particular
paragraphs in communications, it is important to specify the Manual Number and the Issue
Reference.
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
The information provided remains the copyright of Brush Electrical Machines Ltd., and is not to be
copied or disclosed to a third party without the written approval of the Technical Director at the
contact address given hereafter.
1.4 Feedback
We are constantly seeking to improve the quality and reliability of our products, and we actively
encourage user feedback.
Any comments should be addressed to your usual representative, or to our Service Department
at the contact address given hereafter.
1.5 Service & Spares
Quotations for Service and Spares can be obtained from our Service Department at the contact
address given hereafter.
Authorised users can also access spare parts information provided at the Web Site address given
hereafter.
1.6 Contact Address
Brush Electrical Machines Ltd.
PO Box 18
Loughborough
Leicestershire
LE11 1HJ
England
E-Mail: service.sales@bem.fki-et.com
spares.sales@bem.fki-et.com
Every precaution should be taken to minimise risk. When acted upon, the following precautions
should considerably minimise the possibility of hazardous incidents.
Delivery Checks: Check for damage sustained during transport. Damage to packing cases must
be investigated in the presence of an Insurance Surveyor.
Installation: Where installation is made by engineers other than Brush Electrical Machines Ltd.
personnel, the equipment should be installed by suitably qualified personnel in accordance with
relevant legislation, regulations and accepted rules of the industry. In particular, the
recommendations contained in the regulations with regard to the earthing (grounding) must be
rigorously followed.
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
It is important to be aware that control unit terminals and components may be live to
line and supply voltages.
Before working on a unit, switch off and isolate it and all other equipment within the confines of
the same control cubicle. Check that all earth connections are sound.
Adjustment and fault finding on live equipment must be by qualified and authorised personnel
only, and should be in accordance with the following rules:
Ø Read the Instruction Manual.
Ø Use insulated meter probes.
Ø Use an insulated screwdriver for potentiometer adjustment where a knob is not provided.
Ø Wear non-conducting footwear.
Ø Do not attempt to modify wiring.
Ø Replace all protective covers, guards, etc. on completion.
Operation & Maintenance: Engineers responsible for operation and maintenance of equipment
supplied under this contract should familiarise themselves with the information contained in this
manual and with the recommendations given by manufacturers of associated equipment. They
should be familiar also with the relevant regulations in force.
Ø It is essential that all covers are in place and that all guards and/or safety fences to protect
any exposed surfaces and/or pits are fitted before the machine is started.
Ø All adjustments to the machine must be carried out whilst the machine is stationary and
isolated from all electrical supplies. Replace all covers and/or safety fences before restarting
the machine.
Ø When maintenance is being carried out, suitable WARNING signs should be prominently
displayed and the necessary precautions taken to ensure power is not inadvertently switched
on to the equipment whilst work is in progress, or is not yet complete.
Ø When power is restored to the equipment, personnel should not be allowed to work on
auxiliary circuits, eg. Heaters, temperature detectors, current transformers etc.
1.8 Protection And Monitoring Devices
WARNING: It is essential that any protection or monitoring device for use with generators or
ancillary equipment should be connected and operational at all times unless specifically stated
otherwise herein. It should not be assumed that all necessary protection and monitoring
devices are supplied as part of Brush Electrical Machines Ltd. scope of supply.
Unless otherwise agreed, it is the responsibility of others to verify the correct operation of all
protection and monitoring equipment, whether supplied by Brush Electrical Machines Ltd. or
not. It is necessary to provide a secure environment that ensures operator safety and limits
potential damage to the generator and ancillary equipment. If requested, Brush Electrical
Machines Ltd. would be pleased to provide advice on any specific protection application
issues or concerns.
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
To avoid this occurrence it has been the practice in the past to detect a single rotor earth fault by
use of brushes and sensitive earth fault current relays, and to take the machine out of service for
investigation and repair of the fault at the earliest opportunity.
The Brush PRISMIC R10 Rotor Earth Fault Monitor dispenses with the need for brushes by using
fully static techniques to detect a single rotor earth fault on the shaft, and transmit the information
to a stationary receiver, thereby giving enhanced reliability and reduced maintenance costs.
Block Diagram
Brushless Generator
Rotating Assembly
Excitation
AVR
Source
Exciter
Transmitter
Receiver
Aerial
Receiver Unit
Detector
Loss Of Alarm
Excitation & Output
Detector Contacts
Test
Switch
Loss Of
Power
Power Supply
Supply
Detector
The above diagram shows the basic system. The transmitter has 3 electrical connections to the
rotor i.e. to earth, rotor positive (F1) and rotor negative (F2). The rotor voltage provides the power
supply for the unit, from which it generates its own isolated d.c. source that is used as the earth
fault detection supply. The negative of this isolated source is tied to earth (ground), the positive to
the rotor negative (F2). During healthy conditions, the current flowing from the isolated d.c.
source is negligible and the transmitter produces a high frequency signal that is detected by the
receiver aerial, and the receiver indicates no fault.
Any earth fault on the rotating assembly, either on the armature or the rotor winding, will cause a
current to flow from the d.c. source. This current is detected and is used to remove the
transmitted high frequency signal. By removing the signal, the detection system becomes 'fail-to-
safe' in that a loss of transmitted signal is detected as an earth fault condition.
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
The auxiliary supply required by the receiver for its power supplies is normally provided by the
automatic voltage regulator (AVR) excitation source, usually a permanent magnet generator
(PMG). During run up on AVR over flux control, or during normal off load transients, the available
rotor voltage may be too low to ensure correct transmitter operation. To overcome this, a circuit is
incorporated in the receiver to inhibit output relay energisation on either low exciter field voltage
or low auxiliary a.c. supply voltage. A time delay stage within this circuit allows for the rotor
voltage to build up prior to giving a permissive output.
The standard transmitter is Part No.961502100. In addition, there is a low voltage version
(963226001) and high voltage version (963256401).
Transmitter Assembly
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
The previously available unboxed receiver assembly complete with Perspex cover and test
pushbutton, as shown above, has been superseded by the boxed unit for panel mounting as
shown in the illustration shown on Page 9.
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
The system is least sensitive when the fault is present on the negative of the field, and in this
case the sensitivity is approximately 12kΩ.
On a machine with a full load rotor voltage of 200V, the sensitivity to a fault on the positive of
the field would be approximately 157kΩ.
5) Temperature
Receiver: Operating -25ºC to +85ºC
Aerial and Transmitter: Operating -25ºC to +70ºC
Storage: -40ºC to +100ºC
If the exciter field voltage falls below the preset level, the inhibit will be applied
instantaneously.
The maximum continuous exciter field voltage at this input is 400V d.c.
9) Test Facility
Operation of an external test pushbutton or keyswitch when the machine is running and
excited, will simulate an earth fault and produce an alarm signal.
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
The transmitter may be mounted at a larger radius provided the speed is reduced
accordingly.
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
The receiver, aerial and transmitter should be connected as shown in Section 11 - Appendix B -
Electrical Connections.
5.2 Aerial Cable
Three core screened cable should be used to connect the aerial to the receiver. The screen
should be connected to terminal 3 at the aerial.
The length of cable should be such that the capacitance of each core to the screen does not
exceed 0.1µF, and the resistance of each core does not exceed 10Ω. The current flowing in the
aerial cable does not exceed 20mA.
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
Pay particular attention to the position of the aerial in relation to the transmitter, also to the
polarity of the rotor connections to the transmitter.
Ensure that the transparent windows on the transmitter and aerial are clean.
6.2.2 Wiring Between Aerial And Receiver
Check that three core screened cable has been used, and that the screen is connected to earth
at the aerial (Terminal 3).
6.3 Receiver
6.3.1 Supply
Ensure that the receiver is connected on the correct voltage terminal, and that the handbag links
are in the correct position according to the information given in Section 12 - Appendix C -
Receiver Link Settings).
6.3.2 Operating Frequency
Select the unit for the infra red transmitter frequency by setting switches 1 to 4 'ON' and switches
5 to 8 'OFF'.
6.4 Commissioning Tests
1) Run the set up to rated speed with auto excitation selected using the AVR overflux limiter to
allow the voltage to build up gradually. If the overflux limiter is not included in the AVR, switch
on excitation at rated speed.
3) Set up the supply inhibit circuit by adjusting RV1 so that the d.c. voltage on TP4, with respect
to TP1, is 1.3 times the voltage measured across TP5 and TP1 (approximately 6V).
5) Check that no alarm signal is given, and protection operated LED3 is off.
6) Suppress excitation and again check that no alarm signal is given. Check that LED2 is off.
7) Apply excitation and check that no alarm signal is given as the excitation builds up. Operate
the test pushbutton or keyswitch and check that an alarm is given after approximately 1
second.
Release the test button, or turn the keyswitch to the normal position, and check that the alarm
is cancelled.
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
9) If the normal mode of operation is to run down the machine with the excitation turned on, the
machine should be run down with excitation on to confirm that no earth fault alarm is given.
6.5 Functional Check
Having followed the preceding commissioning procedure, it is desirable to check that an earth
fault condition is correctly detected. It is imperative that, prior to this test, it is confirmed that no
rotor earth fault exists. (This should have been verified by the preceding commissioning checks).
Using a short light gauge wire (22 SWG or less) put an earth fault on the rotor between
transmitter F2 stud and the adjacent earth screw connection. Run the set up to speed, and
check that when auto excitation is selected, an earth fault indication is given. Switch off excitation,
shut down the set, and remove the earth fault.
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
Static testing with the components mounted in position on the machine is more realistic since the
position of the aerial relative to the transmitter is not changed. It may also be easier since the
transmitter need not be removed from the shaft.
WARNING: When working on the transmitter ensure machine shaft will remain
stationary throughout.
8.2 Static Testing With Transmitter On The Shaft
1) Position the transmitter (by rotating the shaft) so that the LED emitters are facing the aerial.
See Clause 5.1.
2) Disconnect rotor connections F1 and F2 from the transmitter terminals, and connect a 30V
d.c. power supply rated at 50mA, with the positive to F1 (this is the right hand terminal when
viewing from the end carrying the infrared emitters) and the negative to F2.
3) Check that the supply current to the transmitter, without a simulated earth fault, is between 25
and 35mA with a 30V supply, and that when terminal F2 is connected to the transmitter
housing, the current drops to between 15mA and 22mA.
4) Connect the receiver as shown in the diagram below. It may be necessary to temporarily
select different power supply links to suit the a.c. supply available for testing.
Connection Diagram For Static Testing
Screen may be omitted if
distance is less than 1 metre
Approx. 300mm
Aerial Transmitter
15 5 14 4
1 1
2 2
IR Signal (+ve)
9, 10 or 11 3 3 F1 F2
AC (Fit correct link)
Supply
12 4 Test Switch (Close to test) 30 Vdc
50mA
Receiver
5) The exciter field voltage signal required at receiver terminals 15 and 5, may be obtained by
linking terminals 14 to 5, and terminals 2 to 15, after temporarily disconnecting the cable
connected to terminal 5.
6) No earth fault should be given when the receiver and transmitter supplies are on (LED3
should be off). The supply present indicator (LED4) should be on, and both inhibit release
LED’s (LED1 and LED2) should be on.
7) Temporarily link transmitter terminal F1 then F2 to the transmitter casing, and check that the
receiver gives earth fault indication (LED3 on for each case).
If test (6) results in a continuous earth fault indication, and LED's 1, 2 and 3 on the receiver are
on, the signal at the input of the receiver (Terminals 1 and 2) should be checked with an
oscilloscope.
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
Note: When the machine is rotating, this signal will occur in bursts with at least one burst of
duration 2ms or more each revolution i.e. each 16ms on a 3,600rpm machine, or each 20ms
on a 3,000rpm machine. There may be other shorter bursts due to spurious infrared and
reflections in the machine, and these should be disregarded.
With the simulated earth fault of test (7) above, the 20kHz signal should be completely removed.
(Ignore spurious pulses that may occur due to background infrared signals.) If the signal is not
removed, the transmitter is faulty.
If the signal is present at the receiver and an earth fault alarm persists, ensure that the test switch
is set to the normal running position (normally open) and adjust tuning as described in Clause
7.2.1.
If it is not possible to tune the receiver, a faulty receiver is indicated and it should be replaced.
8.3 Static Testing With Transmitter And Aerial On Bench
Remove the transmitter and aerial from the machine, and connect to the receiver as shown in the
diagram above. A 30V 50mA d.c. supply should then be connected to the transmitter.
The aerial should be placed approximately 300mm from the transmitter, with its window pointing
towards the infrared emitters on the transmitter.
WARNING: Care should be taken that stray infra red emissions do not activate fire protection
systems.
0 Volts
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
In addition, the ability of the transmitter to detect an earth fault should be confirmed annually by
performing the functional test described in Clause 6.5.
Also, each time the end cover is removed for other maintenance tasks, the infrared emitters of the
transmitter and the infrared sensitive area of the detector should be cleaned with a soft cloth. This
will be required to be done annually in a normal machine environment, and more frequently in a
dirty environment.
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
1 Aerial Terminal 1
2 Aerial Terminal 2
14 Aerial Terminal 4
3
To Test Switch (Close to test)
4
+ve
5
To Exciter Field
15 -ve
Normally Open
7
13
Output Relay Contacts
Normally Closed
6
8
264V/400V 9
Auxiliary AC Supply 220V 10
(Select appropriate Link) 110V 11 AC Supply
(Normally PMG)
Common 12
Infra-Red Emitters
Aerial Module
(White) 1 To Receiver Terminal 1
(Black) 2 To Receiver Terminal 2
(Red) 4 To Receiver Terminal 14
(Grey) 3
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
Note: The following items are 'unconfigured' assemblies, which will need to be configured as
the originally supplied unit and commissioned in accordance with Section 6 herein.
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005
TP0000008 (H) R10 REFM Instruction Manual.doc © Brush Electrical Machines Ltd. 2005