Professional Documents
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ALTERNATOR TRAINING
Ersin ERDALI
June’ 06
INCLUDE OF
INCLUDE OF ALTERNATOR
ALTERNATOR TRAINING
TRAINING
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1. Base Electrical Information
Electromagnetic Field :
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1. Base Electrical Information
Faraday’s Law :
Any change in the magnetic environment of a coil of wire will cause a
voltage (emf) to be "induced" in the coil. No matter how the change is
produced, the voltage will be generated. The change could be produced
by changing the magnetic field strength, moving a magnet toward or
away from the coil, moving the coil into or out of the magnetic field,
rotating the coil relative to the magnet, etc.
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1. Base Electrical Information
Electrical Definations:
Resistance, Unit : Ohm (R)
Resistance is a measure of the degree to
which an object opposes the passage of
electric current
Measurement Device : Ohmmeter
V IxR
Voltage is the difference of electrical
potential between two points of an electrical
network
Measurement Device : Voltmeter Circuit
Component
1 Ampere : 6,28x10
18 electron /s
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1. Base Electrical Information
• Alternating Current (AC) : • Direct Current (DC) :
AC current is changed way and DC current is not changed
strenght by the time. way and strenght by the
time.
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2. Alternator Operation Principle
When the magnetic field
around a conductor
changes, a current is
induced in the conductor.
In a alternator, a rotating
magnet called the rotor
turns within a stationary
set of conductors wound
in coils on an iron core,
called the stator. The
field cuts across the
conductors, generating
an electrical current, as
the mechanical input
causes the rotor to turn.
Permanent Magnetic Field
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2. Alternator Operation Principle
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2. Alternator Operation Principle
Magnetic field on the windings induce alternating (AC)
voltage in main stator.
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2. Alternator Operation Principle
Voltage regulator
senses induced voltage
in main stator to take a
Uyartýn
Gerilimi DC
referance.
Sensed voltage
compares regulator
setting values (400 V
AC, 50Hz).
Excitation voltage
Referans
Giriºleri
rotor.
Excitation
Rotor
Voltage AC
Output of
Diodes Main
Rotor
Voltage DC
Excitation rotor
voltage realizes
main rotor windings
which rectified DC
voltage.
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3. Alternator Parts and Functions
Alternators Which We Use :
Stamford / England
(12 toes)
Leroy-Somer / France
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3. Alternator Parts and Functions
Terminal Box
Alternator A.V.R.
Stator
Main
Rotor
Rotating
Excitation Rotor Diodes Plate
and Varistor
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3. Alternator Parts and Functions
Alternator Parts (MccAlte Eco 37) :
NAME NAME
1 real seal 23 electronic regulator
2 casing 24 auxiliary terminal board
3 grid 28 cover stay bolt
5 users terminal board
39 protection screen
7 rear cover
40 fixing ring
8 frame with stator
9 front cover 42 parallel device
9A front cover MD 35 59 coupling hub
10 exciting stator 60 disc plates
11 rotating diode bridge 70 radio disturbs suppressor
12 hub
94 rear case
13 exciting armature
14 rotor 95 termin.brd.side panel
15 fan 96 termin.brd.front panel
16 exterior flange bearing cover 97 termin.brd.rear panel
17 drive-end bearing 98 regulator carrying panel
18 interior flange bearing cover
99 disc blocking ring spacer
19 rear bearing
104 component-carryng panel
20 terminal box
22 diode holder washer 123 ring spacer
143 exciter stay bolt
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3. Alternator Parts and Functions
Terminal Box (Mecc Alte ECO 34)
Neutral
Point
Paralleling
Transformer
Output
Points
U- V- W
RFI
Suppressor
A.V.R.
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3. Alternator Parts and Functions
Terminal Box (Mecc Alte ECO 3)
R.F.I.
Suppressor
Output
Points
A.V.R.
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3. Alternator Parts and Functions
Terminal Box (Stamford P7 Series) :
Terminal Box
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3. Alternator Parts and Functions
Main Stator :
• Main stator which is made of high quality
siliceous laminations is mounted by means
of supporting ribs in a sheet steel body.
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3. Alternator Parts and Functions
Main Rotor :
The rotor is salient-pole type. Damper windings are
placed into the rotor as a standard feature for parallel
work and unbalanced loads. Fan, the main rotor,
excitation rotor and the rotating diodes are fitted to
shaft . The entire rotor is dynamically balanced.
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3. Alternator Parts and Functions
Voltage Regulator (AVR) :
This is the most important element of the alternator. At asymmetrical
loads, the voltage regulator senses three phases as a reference therefore
maximum voltage asymmetry is 5%. Electrical and thermical tests are
applied before mounting on the alternator. The output voltage could be
adjusted manually by a potentiometer.
Reference
Alternator LOAD
(Sensing)
Voltage
Regulator
Setting
Values
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3. Alternator Parts and Functions
Voltage Regulator (AVR) :
To remotely regulate the voltage there are
terminals for potentiometer connection.
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3. Alternator Parts and Functions
Voltage Regulators Which We USe :
Mecc Alte
SR 7
UVR 6
Stamford
SX 460 SX 440 SX 421 SA 465
S : Self excited
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3. Alternator Parts and Functions
Mecc Alte UVR6 Voltage Regulator Technical Features:
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3. Alternator Parts and Functions
Mecc Alte SR7/2 Voltaj Regulator Setting Potentiometer :
Voltage
Setting
Stability
Setting
Factory Settings
(Low speed and
over load)
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3. Alternator Parts and Functions
Mecc Alte SR7/2 Voltage Regulator Terminal Connections :
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3. Alternator Parts and Functions
Stamford MX321 Voltage Regulator Terminal Connections - 1 :
Volts:
Setting generator output voltage.
Stability:
Keeping from voltage oscillation, setting steady
state time .
Stability Selection:
To provide suitable voltage transient.
UFRO:
Setting underfrequence protection border.
Frequency Selection:
Providing for suitable operation of UFRO
protection.
Droop:
Enable voltage droop (5 % on full load).
Trim:
To provide regulator input and accessories uotput.
Exc Trip :
Over excitation cutting level (5Vdc - %5, 8-15 s
delayed).
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3. Alternator Parts and Functions
Stamford MX321 Voltage Regulator Terminal Connections - 2 :
DIP:
Setting frequence-voltage curve.
Over/V:
Shuting down excitation voltage When
Ýnput reference voltage to AVR faults
(Between terminal E1-E0; 300 Vac, 8-15s
delayed).
I-Limit:
Maximum short circuit current.
Dwell:
Voltage tidy up time after on full loaded.
RMS:
Loading.
RAMP:
Setting to reach nominal value of output
voltage by cranking. Factory setting is 3
seconds and it’s enough for many
applications.
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3. Alternator Parts and Functions
External Voltage Potentiometer Connection :
• Voltage potentiometer
can be connected
terminal 1-2 of all AVR
for Stamfor alternator.
• Normally those
terminals are bridged.
Remove those bridge
when potentiometer
connected.
• POT = 4,7 K
Stamford MX321 Voltage Regulator
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3. Alternator Parts and Functions
Rotating Diode Plate :
•Ac voltage is rectified DC voltage to set the permanent
magnet on main rotor via rotating diodes plate which induce
excitation rotor.
• Rotating diode plate is partitioned positive and negative plate
and there are 3 diodes both plates (total 6 diodes).
1. AC Input
2. Rectifier Plate
3. Diodes – 3 x Negative
4. Diodes – 3 x Positive
5. Varistor
6. DC Output to Main Rotor
7. Plate
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3. Alternator Parts and Functions
Varistor :
Varistors (VDR’s) are a mix of carbon materials that are a high
resistance until subjected to a high pressure.
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3. Alternator Parts and Functions
Excitation Stator and Rotor:
• Excitation stator is provided to
induce magnet for excitation rotor
by DC signal via voltage regulator
(10-15 V).
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3. Alternator Parts and Functions
Voltage Regulator Supply Devices - 1 :
PMG
• Provides a separate fixed source impedence
power to AVR & exciter field that is isolated from
the generator output and is not influenced by
external load conditions.
• The isolated PMG power supply of the excitation
system allows the generator to meet low EMI /
RFI suppression levels to meet MIL-
STD.461C&VDE Class K.
• PMG provides constant power to supply manual
voltage control of the generator & to supply
overvoltage , overcurrent & over excitation
protection circuits.
•Stamford and Leroy-Somer alternators have got
PMG system which we use.
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3. Alternator Parts and Functions
Voltage Regulator Supply Devices - 2 :
AREP
It is auxiliary windings system to induce AC voltage to supply AVR
which is inserted the main stator windings.
Auxiliary windings are thin section. Resistance is lower than main
stator windings.
Mecc Alte alternator has got AREP windings system which we use.
Shunt
AC voltage is provided directly by main stator windings to
supply AVR.
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3. Alternator Parts and Functions
Voltage Regulator Supply Devices - 3 :
When to Choose PMG or AREP :
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3. Alternator Parts and Functions
SITUATION
SHUNT
SHUNT
THE ALTERNATOR DOES NOT HOLD
THE SITUATION
DESENERGIZING OF THE ALTERNATOR
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3. Alternator Parts and Functions
Brush and Ring Mechanism :
-+
- +
-+
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3. Alternator Parts and Functions
Alternator Windings Heater:
• Humidity can be reduced
isolation resistance on
alternator windings. In that
case heater have to insert the
windings for protection.
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3. Alternator Parts and Functions
Bearing :
•Bearing is provided to rotate coupled components
of alternator mandrel (main rotor, excitation rotor,
PMG rotor, rotating diodes, etc.) by stability.
•All alternators in Aksa are single bearing.
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3. Alternator Parts and Functions
Fan and Airconditioning :
• Alternator windings warme up by and by which induce current inside
(J=I2Rt). Warmed windings have to be cooled for efficiency. Fan is used for
cooling system.
• Cooling has to be realized for protection of alternator windings. Therefore
don’t close up air intake and drop ball places.
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3. Alternator Parts and Functions
Thermic Protection Components :
• Thermic sensors use to protect the warmness of windings in alternator (and
in electrical motors).
•PTC thermistor uses in Mecc-Alte ECO 37 – 40 – 43 series alternator by
standard.
Bimetal Contact
PTC Thermistor
PT100 Thermic
Resistor
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3. Alternator Parts and Functions
RFI Suppressor :
• RFI (Radio Frequency Interference)
is noise vibration in alternator
windings because of magnetic field
(>1 kHz).
• Filter with condenser is used to
reduce the noises.
• Standards :
BS EN 50081-50082
VDE 0875
BS 1597
MIL 461
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3. Alternator Parts and Functions
Paralleling Transformer:
• Paralleling transformer is used for
syncronous operation with other alternators
and also with the mains.
• This transformer gives for Mecc Alte Eco
40-43 series alternators. It’s optional for
other alternators.
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3. Alternator Parts and Functions
Blok Diagram For Alternator With PMG :
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3. Alternator Parts and Functions
Alternator With PMG :
Mandrel
Main Rotor
Main Stator
Bearing
Excitation Rotor
Excitation Stator
Rotating Diodes Plate and Varistor
PMG Rotor and Stator
Terminal Connections
Voltage Regulator
Stator Cables
Reference Cables
PMG Cables
Excitation Cables
Main Rotor Excitation Cables
Fan and Air-condition
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3. Alternator Parts and Functions
Block Diagram For Alternator With Transformer :
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4. Technical Knowledges and Numeral Rules
Mains – Generator Voltages :
• Mains in Turkey ;
Phase - Neutral : 220 V AC
Phase - Phase : 380 V AC • For USA;
Frequence : 50 Hz F: 60 Hz
voltage difference between operating voltage •For India and South Africa ;
(380 V AC) and generator nominal voltage F : 50 – 25 Hz
(400 V AC). For our generators ;
Phase - Neutral : 231 V AC
Phase - Phase : 400 V AC
Frequence : 50 Hz
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4. Technical Knowledges and Numeral Rules
Generator Operation Powers :
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4. Technical Knowledges and Numeral Rules
Generator Operation Powers :
Standby Operation
(Operation on limited time) :
Prime Operation
(Operation on unlimeted time) :
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4. Technical Knowledges and Numeral Rules
Generator Operation Powers :
Continuous Operation :
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4. Technical Knowledges and Numeral Rules
Power Quality and Gauge :
•Acceptable values for harmonic distortions according
to IEC 519-1992 standard;
But ;
• Over current
• Unbalance loads
• Operation on low Cos (power factor) loads
• Over ambient temperature
• Harmonics (because of warmness)
• Less air-condition
• Operation on pulverulent places
• Humid places
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4. Technical Knowledges and Numeral Rules
Voltage Unbalance Rate:
Voltage unbalance is rated the biggest of 3 phases output
voltages of alternator (U,V,W) and average output voltage.
For example;
Output voltages of alternator are about 236, 229, 225 volts;
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4. Technical Knowledges and Numeral Rules
Effecting Alternator Of Voltage Unbalance :
• Because of voltage unbalance, A small magnetic field is induced on
alternator windings which is direct opposite main magnetic field.
• Voltage unbalance effects to warm windings up.
Example Calculation :
(Voltage Unbalance)2
Temp. Boost = Nominal Temp x 1 + 2
100
(2,61)2
Temp. Boost = 80C x 1+2 = 80C x 1,136
100
Genset Voltage
Unstable
Critical
Good
Slow
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4. Technical Knowledges and Numeral Rules
Cos Values Of Electrical Loads :
Electrical Heater 1
Incandescent Lamp 1
3 Phases Motors 0,7-0,9
Fluorescent Lamp 0,3-0,5
Neon Lamp 0,4-0,5
Welder Machine 0,4-0,8
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4. Technical Knowledges and Numeral Rules
The Power Triangle :
There are 3 types of electrical powers :
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4. Technical Knowledges and Numeral Rules
Electrical Power Formulas:
Apparent Power (S, kVA)
The inductor does not use any true power. However, to the generator, the
inductor “appears” to be consuming power because there is an opposition
to current (inductive reactance) and voltage drop across it.
The generator power is apparently used by the inductor.The total power
used by the inductor and resistor is called appropriately. Apparent Power.
Apparent power is measured in Volt-Amperes (VA) to distinguish it from
true power.Apparent power for an inductive circuit can be found by
multiplying the total current by the applied voltage;
Q (kVAr) (k
V A)
S 3UI
S
P (kW) Ersin ERDALI
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4. Technical Knowledges and Numeral Rules
Electrical Power Formulas:
True Power (P, kW)
Inductance and resistance characteristics are both present in
industrial motors which consist of many coils of wire.
The coils cause current to lag voltage as in an inductor and because
of coil length, the motor also has resistance.
AC generator is used to provide power to a motor. The resistor is
the only component that comsumes power.
The power used by a resistor is called True Power.
Q (kVAr) (k
S
V A)
P S Cos
P (kW) Ersin ERDALI
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4. Technical Knowledges and Numeral Rules
Electrical Power Formulas:
Reactive Power (Q, kVAR)
We know that reactive loads such as inductors and capacitors
dissipate zero power, yet the fact that they drop voltage and
draw current gives the deceptive impression that they actually
do dissipate power. This “phantom power” is called reactive
power, and it is measured in a unit called Volt-Amps-Reactive
(VAR).
Q (kVAr) (kV
A)
Q S Sin
S
P (kW) Ersin ERDALI
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4. Technical Knowledges and Numeral Rules
Example Calculation For Electrical Powers - 1 :
S 100kVA
A )
V
Q (kVAr) S ( k S 3 U I
P S Cos
P (kW)
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4. Technical Knowledges and Numeral Rules
Example Calculation For Electrical Powers - 2 :
Firstly we should calculate active power output
of gen-set (Cos=0,8 for gen-set and it’s
constant).
Following that ;
P 80 kW idi..
ForCos
Cos 1 için;
=1
P 3 U I Cos
P
I I I 115,6 Amper
80000
3 U Cos
Ampere
3 4001
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4. Technical Knowledges and Numeral Rules
Calculation For Pole Number :
Hz : Frequence
NK
Hz N : Engine speed (rpm)
120 K : Pole number
Example :
We will calculate alternator pole number at 1500 rpm of
engine speed.
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4. Technical Knowledges and Numeral Rules
Suitable Generator Selection - 1 :
A gen-set for 1000 kVA will supply a load for 900 kVA and
Cos = 0,5 . We wiil calculate that; is it suitable power of
generator or not? (For all gen-set; Cos = 0,8 constant).
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4. Technical Knowledges and Numeral Rules
Suitable Generator Selection - 2 :
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4. Technical Knowledges and Numeral Rules
Suitable Generator Selection - 3 :
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4. Technical Knowledges and Numeral Rules
Relation Between Voltage and Speed :
• Alternator output voltage is rate of 75% at engine
speed rate of 75%.
• Alternator output voltage is rate of 10% at engine low
speed
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4. Technical Knowledges and Numeral Rules
Relation Between Voltage and Current :
No voltage reduction if no over load current (speed is fixed).
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4. Technical Knowledges and Numeral Rules
Windings Connections For 12 Lead Alternators :
We use difference connections on alternator to provide difference voltages by easily.
Accordingly possibility 115/200/230/400 Volts 50Hz on 12 lead alternators.
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4. Technical Knowledges and Numeral Rules
Windings Connections For 12 Lead Alternators :
VDC VARÝSTOR
VDC V
- - W
Reference
AVR
U
V
W Points
IP 2 3 C H
IP : Ingress Protection
2 : 1. Number (0-6 or X)
3 : 2. Number (0-8 or X)
C : Addition letter depends on request ( A,B,C,D)
H : Finishing letter depends on request (H,M,S,W)
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5. Protection Class (IP,H-F)
Protection Class According to DIN 40050 Norm:
1.Number
Protection from solid object
0 : Non protected
1 : Protected against solid object greater than 50 mm
2 : Protected against solid object greater than 12 mm
3 : Protected against solid object greater than 2,5 mm
4 : Protected against solid object greater than 1,0 mm
5 : Dust protected
6 : Dust tight
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5. Protection Class (IP,H-F)
Protection Class According to DIN 40050 Norm:
2.Number
Protection from moisture
0 : Non protected
1 : Protected against dripping water
2 : Protected against dripping water when tilted up to 15°
3 : Protected against spraying water
4 : Protected against splashing water
5 : Protected against water jets
6 : Protected against heavy seas
7 : Protected against effect of immersion
8 : Protected against submersion
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5. Protection Class (IP,H-F)
Protection Class According to DIN 40050 Norm:
3.Letter
Addition letter depends on request ( A,B,C,D)
For Dangerous Places ;
A : With hand
B : With finger
C : With equipment
D : With wire
protection to arrive
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5. Protection Class (IP,H-F)
Protection Class According to DIN 40050 Norm:
4.Letter
Finishing letter depends on request
(H,M,S,W)
For Dangerous Places ;
H: High voltage device
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5. Protection Class (IP,H-F)
ISOLATION CLASS OF INSULATOR MATERIALS ACCORDING
TO VDE 0530 STANDARD:
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6. Troubleshooting Guide
Before The Maintenance :
Before any cleaning, lubrication or
maintenance operation, ensure that
the genarator is stationary and
disconnected from the power
supply
The people in charge of the
handling must always wear work
gloves and safety shoes
Do not operate the generator with
protective covers, access covers or
terminal box covers removed.
Disable engine starting circuits
before carrying out maintenance
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6. Troubleshooting Guide
Alternator Maintenance :
Ballbearing Lifetime :
• For the maintenance-free ball bearings
approximately 30.000 hours
• For the lubricatable ballbearings approximately
40.000 hours
Lubricating :
• Lubricating components should be
cleanly.
• Using the suitable oil.
• Operate the alternator and shooting out
the excess oil.
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6. Troubleshooting Guide
Checking The Windings :
Resistance Test
• According the alternator manual values;
measuring and comparing windings resistance
of the main stator-rotor and excitation stator-
rotor.
Insulator Test
•Measure main stator-rotor and excitation
stator-rotor with the meger (1MOhm).
• Before test remove all connections of the
AVR.
• During the test 500 V AC effect the windings.
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6. Troubleshooting Guide
Follow the suggestions below for troubleshooting :
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6. Troubleshooting Guide
Troubleshooting - 1 :
• Alternator does not excite ?
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6. Troubleshooting Guide
Troubleshooting - 2 :
• Low voltage at no load ?
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6. Troubleshooting Guide
Troubleshooting - 3 :
• High voltage at no load ?
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6. Troubleshooting Guide
Troubleshooting - 4 :
• Normal voltage at no load, than lower voltage at
loaded
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6. Troubleshooting Guide
Troubleshooting - 5 :
• Normal voltage at no load, than higher voltage at
loaded
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6. Troubleshooting Guide
Troubleshooting - 6 :
• Unstable voltage ?
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6. Troubleshooting Guide
Troubleshooting - 7 :
• Abnormal Noises ?
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ALTERNATOR TRAINING FINISHED
THANKS
QUESTIONS
ANSWERS
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