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Training Department

ALTERNATOR TRAINING
Ersin ERDALI
June’ 06
INCLUDE OF
INCLUDE OF ALTERNATOR
ALTERNATOR TRAINING
TRAINING

1. Base Electrical Information


2. Alternator Operation Principle
3. Alternator Parts and Functions
4. Technical Knowledges and Numeral Rules
5. Protection Class (IP,H-F)
6. Troubleshooting Guide

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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

 Voltage, Unit : Volt (V)

V  IxR
 Voltage is the difference of electrical
potential between two points of an electrical
network
 Measurement Device : Voltmeter Circuit
Component

 Current, Unit : Ampere (A)


 Moving electrons by voltage and flowing
electrons
 Measurement Device : Ampermetre

 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

 Sine wave current in each  Vector sum of the magnetic


of the coils produces sine field vectors of the stator coils
varying magnetic field on produces a single rotating
the rotation axis. Magnetic vector of resulting rotating
fields add as vectors. magnetic field.

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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

realize excitation stator


via excitation toes of Set
Deðerleri
regulator according to
the difference
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2. Alternator Operation Principle
 Diodes rectify DC
voltage to induced
AC voltage in
excitation rotor to
increase permanent
magnet in main
Inputs of
Diodes

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)

Mecc-Alte Spa / Italy


Eco series 12 toes (Out of Eco 28)

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.

• Main stator grooves and main rotor poles


are designed to minimize distortion on the
waveform. Main stator windings have a
shortened pitch to reduce the harmonic
effects on the waveform.

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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.

Electronic Voltage Regulator


(UVR 6 Mecc Alte)

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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

 MX 341 MX 321 MA 325


M : Permanent Magnet Generator

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3. Alternator Parts and Functions
Mecc Alte UVR6 Voltage Regulator Technical Features:

• 170-270 V AC Supply (with + and 2)


• Capability to sense 3 phases or 1 phase
• Stable for humidity and vibration
• Maximum voltage drop 15%
• Capability to set voltage-stability
• Protection for low frequence and over current
Delay over current protection Yellow Led
Low frequence protection Red Led
Nominal operation Green Led

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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 :

Terminal 1 : Excitation windings negative (-) toe.


Terminal 2 : It should bridge terminal 3 If SR7/2 regulator supply will be
lower then 160 V AC.
Terminal 3 : Excitation windings positive (+) toe and regulator supply.
Terminal 4 : Regulator reference voltage.
Terminal 5 : Common toe for regulator supply, regulator reference voltage
and external potentiometer connection.
Terminal 6 : To bridge terminal 5 for 60 Hz.
Terminal 7 : External potentiometer connection.
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3. Alternator Parts and Functions
Stamford SX440 Voltage Regulator Technical Features :

 Supply voltage 170-250 Vac


 Frequence 50-60 Hz nominal
 Output voltage max. 90 Vdc
(207 Vac input)
 Output Current 4 A DC
(max. 10 seconds 6 A DC)
 Regulation ±%1
 Operation Temp. -40°C - +70°C

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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).

Rotating Diode Plate Elements :

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.

They then becomes a low resistance path to bleed away excessive


pressure by allowing lots of amps to momentarily flow through
the VDR, which has become a momentary low resistance path.
This means that the rating of the device based on it only being
asked to conduct for very short period of time and very
intermittently. A VDR that is continually 'clipping‘ excessive
voltages will get hot and fail.

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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).

•On excitation rotor AC voltage is


rectified DC voltage via rotating
diodes plate and varistor. Thus DC
Current is induced for permanent
magnet for main rotor.

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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 :

 Whole installation with several circuits


 Power cut forbidden
 High rate of distorting loads.
 Starting of a big motor
 Marine, hospitals, stand-by duty, standards in some countries.
 Arep minimum length required
 PMG existing shunt machine to be upgraded

When to Choose SHUNT :

 Single circuit installation


 Power cut acceptable
 Self protection alternator

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3. Alternator Parts and Functions
SITUATION

OVERLOAD OR SHORT CIRCUIT


ON THE INSTALLATION

AREP PMG AREP OR PMG


THE ALTERNATOR CONTROLS THE
SITUATION
DURING 10 SECONDS
THE DEFFECT IS RELEASED
THE BREAKER TRIPS

- THE POWER SUPPLY IS MAINTAINED

SHUNT
SHUNT
THE ALTERNATOR DOES NOT HOLD
THE SITUATION
DESENERGIZING OF THE ALTERNATOR

- THE POWER SUPPLY IS CUTTEN

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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.

•Heaters are 54W-220V for


Mecc Alte ECO 3-28-31-32-34-
38 series. Other heaters are
65W-220V for ECO 40-43-46
(Optional 50W-110V).
Heater

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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

• During the generator (or transformer) V : 480/270, 208/120,

voltage selection, It has to be rate of 5% 240/120

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 :

GENERATOR OPERATION POWERS ACCORDING TO


ISO 8528-1 STANDARDS:

 Operation On Standby Power


 Operation On Prime Power
 Operation On Continuous Power

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4. Technical Knowledges and Numeral Rules
Generator Operation Powers :
 Standby Operation
(Operation on limited time) :

• This genset operation is used variable loads at no


mains.
• Load Measure: 110% (1 hour rate of 10% over
load per 12 hours).
• Annual Operation Time : 500 hours
• Application : working centerum, hotels, hospitals,
housing estate, resting places, factories and other
requested stand-by application places.
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4. Technical Knowledges and Numeral Rules
Generator Operation Powers :

 Prime Operation
(Operation on unlimeted time) :

• On unlimited time, maximum power from


generator for variable loads.
• Load Measure: 90%
• Annual Operation Time: Unlimited
• Application: Industrial and commercial
companies, devoloping companies , cogeneration
applications, rental and marine gensets.

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4. Technical Knowledges and Numeral Rules
Generator Operation Powers :

Continuous Operation :

• On unlimited time, continuous power via


generator.
• Load Measure: 80%
• Annual Operation: Unlimited, continuous.
• Application: Continuous base load, mains,
cogeneration, parallel 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;

For Voltage (V) :


3% THD (total harmonic distortion)

For Current (I) :


5% THD (total harmonic distortion)
•More than limited harmonic distortions will be
effected big problems and sacrifices.
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4. Technical Knowledges and Numeral Rules
Alternator Lifetime :
 On normaly condition, alternator lifetime is
approximately about 100.000 hours for
continuous operation

 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

will be effected shorter than normaly.


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4. Technical Knowledges and Numeral Rules
Efficiency Of Alternator :
Efficiency = Output power / Input Power = kWe / kWm
 Alternator Losts
 Iron lost (Hysterysis and Eddy current)
 Copper lost (Because of windings)
 Friction lost (ballbearing)
 Efficiency of alternator depends on current of load.
 Efficiency of alternator depends on power factor of
load.
 Efficiency is increased if Cos will increase.
 Efficiency is reduced if Cos will reduce.
 Efficiency of alternator is approximately about ;
 For 500-1500 kVA %90-97
 For 0-100 kVA %85-93

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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 = 80C x 1+2 = 80C x 1,136
100

Temp. Boost = 90,9 C


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4. Technical Knowledges and Numeral Rules
Setting Voltage Unbalance With “STAB” Potentiometer :

Genset Voltage
Unstable

Critical

Good

Slow

No Load Full Load

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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 :

Apparent Power (S, VA)


True Power (P, W)
Reactive Power (Q, VAR)

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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  3UI
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 :

 We will calculate full load current for 100 kVA


gen-set at Cos=0,8 and Cos=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  S  Cos  P  100  0,8  P  80kW


CosCos=0,8
For  0,8 için;
P  3 U  I  Cos
P
I I   I  144,5 Amper
80000
3 U  Cos
Ampere
3  400 0,8
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4. Technical Knowledges and Numeral Rules
Example Calculation For Electrical Powers - 3 :

P  80 kW idi..
ForCos
Cos  1 için;
 =1
P  3 U  I  Cos
P
I I   I  115,6 Amper
80000
3 U  Cos
Ampere
3  4001

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4. Technical Knowledges and Numeral Rules
Calculation For Pole Number :

 Hz : Frequence
NK
Hz   N : Engine speed (rpm)
120  K : Pole number
Example :
We will calculate alternator pole number at 1500 rpm of
engine speed.

NK 120 Hz 120 50


Hz  K  K  K  4 Kutuplu
poles
120 N 1500

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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).

 At the first we should calculate true power and reactive


power both gen-set and load. Following that;

For Gen-Set : Sgen = 1000 kVA Cos ö = 0,8

For Load : Sload = 900 kVA Cos ö = 0,5

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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 :

 Suitable Generator Selection :

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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

• This graph is from Mecc-


Alte alternator.

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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).

 Voltage is reducing on short circuit. Therefore short circuit open


settings of thermic-magnetic circuit breaker should be according to
3ln.

• This graph is from Mecc-


Alte alternator.

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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.

 Series Star  Parallel Star  Series Delta


 For 3 Phases  For 3 Phases  For 3 Phases
Sysytems, Sysytems, Sysytems,
 400 Vac (L-L),  200 Vac (L-L),  230 Vac (L-L),
With neutral, No neutral
With neutral,
 
115 Vac (L-N)

230 Vac (L-N)


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4. Technical Knowledges and Numeral Rules
Windings Connections For 12 Lead Alternators :

115 Vac 346 Vac


(L-
(L-L) (L-
(L-L)

 Parallel Delta  3 Phases Zig-Zag


 For 3 Phases  For 3 Phases Sysytems,
Sysytems,  346 Vac (L-L),
 115 Vac (L-L),  With neutral.
No neutral,  Alternator output power
multiple 0,866 (346/400)

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4. Technical Knowledges and Numeral Rules
Windings Connections For 12 Lead Alternators :

230 Vac 230 Vac


(L-
(L-L) (L-
(L-L)

 Single Phase Parallel Zig-Zag  Double Delta


 For Single Phase Sysytems,  For Single Phase Sysytems,
 230 Vac (L-L),  230 Vac (L-L),
 With neutral,  With neutral,
 Usually this connection uses  Usually This connection uses
in Europe’s countries. in Asia’s and America’s
countries. This is the same
connection type of single
phase parallel zig-zag.
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4. Technical Knowledges and Numeral Rules
Alternator Electrical Drawing :
Excitation Uncontrolled 3 Phases Main Main
Excitation
+ Stator
U
Rotor Bridge Rectifier + Rotor Stator

VDC VARÝSTOR
VDC V
- - W
Reference
AVR
U
V
W Points

170-250 V AC (PMG, AREP, Shunt)


Voltage Regulator Supply

PMG Stamford, Leroy-Somer


AREP Mecc Alte
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5. Protection Class (IP,H-F)
IP (Ingress Protection) Code:
 The International Protection code, sometimes called the Ingress
Protection code, classifies the protection given by an enclosure against
the touching of live parts, contact with moving parts and protection
against the ingress of solid bodies.
 It additionally specifies protection against the harmful ingress of liquids.
Two (sometimes 3) digits are used to describe its protection rating,
called the IP code.

 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

 M: Testing against water input demaged when the


moving parts act (exp: rotor)
 S : Testing against water input demaged when the
moving parts stop (exp: rotor)
 W: Suitable to use on specified weather condition
and addition protection features

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5. Protection Class (IP,H-F)
ISOLATION CLASS OF INSULATOR MATERIALS ACCORDING
TO VDE 0530 STANDARD:

• CLASS H ISOLATION : • CLASS F ISOLATION :

Allowable maximum Allowable maximum


temperature is about temperature is about
180°C’dir. (Operation 155°C’dir.
temperature is about
130°C)

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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 :

• Study the problem thoroughly before acting.


• Refer to the alternator system diagrams.
• Check the control unit and all cable connections
• Do the easiest and most logical things first.
• Find and correct the cause of the problem.

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6. Troubleshooting Guide
Troubleshooting - 1 :
• Alternator does not excite ?

Type of Troubleshooting Solving the trouble

Faulty fuse Substitute fuse


Low permanent voltage Increase speed 15%.
No permanent voltage Shock the main rotor by
polarity.

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6. Troubleshooting Guide
Troubleshooting - 2 :
• Low voltage at no load ?

Type of Troubleshooting Solving the trouble


Voltage potentiometer is Set the voltage potentiometer
out of balance
Regulator is protected Check engine speed
Faulty windings Check the windings
Faulty regulator Substitute the regulator

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6. Troubleshooting Guide
Troubleshooting - 3 :
• High voltage at no load ?

Type of Troubleshooting Solving the trouble


Voltage potentiometer is Set the voltage potentiometer
out of balance
Faulty regulator Substitute the regulator

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6. Troubleshooting Guide
Troubleshooting - 4 :
• Normal voltage at no load, than lower voltage at
loaded

Type of Troubleshooting Solving the trouble


Current too high, power factor
Regulator is protected lower than 0.8, speed lower than
4% of rated speed.
Faulty regulator Substitute regulator
Faulty diodes Check diodes

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6. Troubleshooting Guide
Troubleshooting - 5 :
• Normal voltage at no load, than higher voltage at
loaded

Type of Troubleshooting Solving the trouble


Faulty Regulator Substitute regulator

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6. Troubleshooting Guide
Troubleshooting - 6 :
• Unstable voltage ?

Type of Troubleshooting Solving the trouble


Unbalance engine speed Set the engine speed

Faulty regulator Substitute regulator

Stability potantiometer is Regulate stability of regulator by


out of unbalance acting on “STAB.” potentiometer.

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6. Troubleshooting Guide
Troubleshooting - 7 :

• Abnormal Noises ?

Type of Troubleshooting Solving the trouble


Faulty ballbearings Substitute ballbearings

Unstuck assembly Check the assembly bolts. If


it needs, substitute bolts

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ALTERNATOR TRAINING FINISHED

THANKS

QUESTIONS

ANSWERS
Ersin ERDALI
93

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