Aeolos - H 20KW

20kW GENERATOR PERFORMANCE

TEST REPORT

Aug /26 th /2009

20kW generator performance

test program
Test Equipment
InverterFRN400G11S-4CX

1 set

MotorY2355M-4

1 set

GeneratorAEOLOS-H 20kW

1 set

Reduction gearNDAD400-I

1 set

bridge rectifier MDC500A/3600V

3 sets

Load

91

a number of Resistance

Multimeter

2 pieces

Current-clamp

2 pieces

PK Screen

1 pieces

Industrial Personal Computer(IPC)

1 set

Frequency meter

1 piece

Tachometer

1 piece

Current Display Meter

1 piece

Voltage Display Meter

1 piece

Test Reference
Test mainly application on the following criteria:
GB/T1029-2005 three-phase synchronous generator test method.
GB755-2000 rotating generator fixed and performance.
GB/T11026-1989the heat resistance evaluation and classification
of the electrical insulation.
GB/T20160-1999 rotating generator insulation resistance test.
JB/T9578-1999 technical conditions for the rare earth permanent
magnet synchronous generator.

Test Project
1.Determination of insulation resistance.
2.Determination of cold-winding DC resistance.
3.No-load performance test.
4.Load performance test.
5.Voltage regulation rate test.
6.Three-phase stability short-circuit test.
7.Determination of the three-phrase stability short-circuit noload performance.
8.Stator winding withstand voltage test.
9.No-load performance measurement after.

After the measurement of the insulation resistance , every

loop must discharge through being connected to the motor
housing which has been reliably grounded.
During measuring, the data should not be recorded before
the meter pointer becomes stability as while as the measurement
temperature data.
The insulation resistance tested at each different temperature
can be corrected in accordance with the 40 giving in the
standard. And the correction formula is as follows:

R C =K T R T

Note

K T =(0.5)

(40-T)/10

RC :the insulation resistance value corrected to 40 ,

the unit for the M
KT: the temperature coefficient of insulation resistance
at the temperature T;
RT: the measured insulation resistance value at the
temperature T the unit for the M

According to the national standard provisions, the

recommended 4 0 minimum i ns ulation r esis tance value
i s 5 M, t h en t he m i nimum i nsul ation resis tance value o f
each temperature can be calculated.

Data recorded in the

following table:
Measurement
Project

Insulation
resistanceM

Temperature

A relative housing

>1000

34

B relative housing

>1000

34

C relative housing

>1000

34

AB two-phase

>1000

34

BC two-phase

>1000

34

AC two-phase

>1000

34

Test Method
1.Determination of insulation
resistance
The insulation resistance between the three-phase windings
and motor housing , the insulation resistance between the
three-phase windings and the insulation resistance between
the bearings and motor housing were tested by the 500V
megohm meter , other windings which does not participate
in the test , embedded temperature detector are connected
with iron core or motor housing for electrical connection.
Measurement needs to be connected with both ends of each
phase, and then tested.

Conclusion: After correcting the 34 insulation resistance

by using the above formula , It can reach that the allowed
minimum insulation resistance value at thi s temperature
is approximately 7.6M. As the measured value is much
greater than the specified one, so this generator insulation
resistance meets the requirements.

2.Determination of cold-winding

Data recorded in the

following table:

DC resistance
Master meter and multimeter are used for winding DC resistance
measurement . Measure the DC resistance of each phase
winding with rotor stationary, the test current cannot exceed
10 of the rated current , and the electricity period will not
take more than 1min.
DC resistance should be measured in cold state , and the
temperature difference between winding surface and surrounding
air should be within 2K , after correcting the error caused
by wire(lead wire) length, the difference between each phase
or each branch winding DC resistance should not exceed 2
of minimum.

Data recorded in the

following table:
Measurement
Project

Measurement
ResultsM

Generator
Generator
Output line
speed (rpm) voltage Uab
V

Generator
Output line
voltage Ubc
V

Generator
Output line
voltage Uca
V

Bridge
Rectifier
DC voltage
Vdc

DC
voltage
/Line
voltage

80.0442

80.07336

79.8984

110.3609

1.37956

60

100.427

100.4562

100.3104

139.5569

1.38954

72

120.9848

120.9848

120.9265

167.585

1.38413

84

141.1636

141.1636

141.1344

194.7373

1.3781

96

161.6922

161.663

161.5464

223.6414

1.38267

108

182.0167

181.9876

181.9584

250.5017

1.375

120

200.8541

200.8249

200.7374

278.8218

1.38728

132

221.441

221.4119

221.3827

307.1419

1.38567

144

241.5906

241.5614

241.4448

334.8781

1.38525

48

Temperature

DC resistance of A phase

237.5

35

DC resistance of B phase

236.8

35

DC resistance of C phase

238.3

35

Rotation speed-DC voltage diagram

450
400

ConclusionAf ter measurement and calculation , it is

conclude that the difference between arbitrary two-phase
DC cold resistance does not exceed 2, meets requirements.

350
300
250
200
150
100

3.No-load characteristic test

50

The No-loaded generator is dragged by an electric motor.

The output frequency of inverter is controlled to make the
generator rotation speed increase gradually from 40
(40 rpm) of rated speed to 120 (100 rpm ) meanwhile
measure the output phase voltageline voltageoutput DC
voltage of bridge rectifier, then record the voltage waveform
of generator and analyze the relationship between phase ,
line and DC.
If three-phase is symmetric, except for recording three-phase
voltage when the generator reach rated voltage, you only need
to record the data of one of the three phases.

Gearbox

Inverter

Disconnector Inverter

48

60

72

84

96

108

120

132

144

Rotation speed(rpm)

Conclusion:
1 . Through the above data and graphics , i t can be seen that
g en e r a t o r output vol tage is proportional to the generator
r o t a t i o n s p e e d ; i t i n c r ea s es as the rotation speed dose .
2. The rectified DC voltage of the generator is also
p r o p o r t i o n a l t o t h e l i n e vo l t age , and t he rat io bet ween
them is about 1.38.

Experimental principles recorded

in the following picture:

380V
power
source

Motor Gearbox

3. The ratio between generator no-load DC voltage and

rotation speed is 5.7V/rpm.
Each additional turn's increases, the g enerator no-load
output DC voltage will increase 6.9V.

Motor

4.Load performance test

Udc

Maintain the generator rotation speed, change the load

resistance, measure the generator rotation speed f,requency,
and rectified voltage ,current, calculate the generator output
power, and look for the maximum output power under this
rotation speed. Since in the actual test , the method of
keeping the speed and then changing the resistance is
relatively time-consuming, so we make resistance unchanged,
then change the speed, and record the power change under
the same load and different speed.
According to the field condition , our test i s to measure
rectified output DC voltage, DC current, and power by
using an available inverter wave and changing the inverter
duty ratio M.

114.249 48.59

N=50rpm

Experimental principles recorded

in the following picture:

Load

Gearbox

Inverter

Disconnector Inverter

Motor Gearbox Motor

rectifier
bridge

Generator load experimental principle

Data record

N=50rpm

Udc

Idc

P(Kw)

Udc

Idc

P(Kw)

137.869

0.35

0.048254

164.812

0.46

0.075

137.256

0.441

0.06053

164.229

0.57

0.09427

137.110

0.574 0.078701

162.596

1.13

0.18438

135.711

1.12

0.151996

161.459

2.73

0.44078

134.457

2.31

0.310595

160.234

5.13

0.82216

134.049

3.829 0.513272

158.485

8.4

1.33127

133.174

5.901 0.785858

156.735 12.45

1.95072

132.007

8.33

154.548 17.21

2.65915

130.987 11.179 1.464301

151.851 22.75

3.4546

129.295 14.469 1.870776

148.512 28.82

4.27996

127.505 19.089 2.433943

145.188 35.26

5.11917

1.099621

24.22 3.031954

N=60rpm

42.19

5.96761

137.694 49.47

6.81156

119.988 35.819 4.297835

133.713 57.14

7.64051

4.927049

129.704 64.79

8.40285

125.184

122.589 29.869

117.311

42

3.6616

141.45

5.55181

Idc

125.7379 72.57

P(Kw)

9.124675

6.16996

121.6264 80.51

9.792625

6.72501

118.0397 88.62

10.46068

104.801

69.3

7.26271

113.9194 96.37

10.9783

101.914

76.3

7.77605

109.7874 103.95

11.4124

98.998

83.6

8.27566

105.4134 110.95 11.69562

95.907

90.89

8.71615

100.5145 117.48 11.80855

92.75796 97.83

9.07405

96.02388 123.49 11.85837

89.667 104.42

9.36294

91.75194 128.99 11.83499

86.022 110.67

9.52006

87.0426 133.82 11.64795

82.756 116.62

9.65101

82.931 138.25 11.46522

N=60rpm

79.344 121.92

9.67359

78.64452 142.3

75.933 126.93

9.63821

74.62044 145.88 10.88563

72.463 131.53

9.53101

70.88796 148.98 10.56096

135.6

9.37939

67.2138 151.81 10.20366

66.135

139.3

9.21259

63.91872 154.35 9.865854

62.986

142.8

8.99434

60.62364 156.51 9.487963

60.245 145.83

8.78552

57.47436 158.39 9.103306

57.533 148.52

8.5447

55.06866 160.14

8.81864

54.675 151.08

8.26035

52.07976 161.7

8.421297

11.1908

153.3

7.98383

49.51368 163.12 8.076721

49.514 155.28

7.68853

46.8018 164.38 7.693327

46.685 157.09

7.33396

45.096 158.67

7.15533

Udc

Idc

P(Kw)

Udc

Idc

P(Kw)

191.902

0.49

0.094032

219.167

0.53

0.115062

191.086

0.65

0.124397

218.379

0.71

0.155923

189.044

1.34

0.254076

215.58

1.53

0.328975

187.936

3.2

0.601208

214.384

3.63

0.777358

186.245

5.97

1.112068

212.606

6.79

1.443592

184.233

9.8

1.805482

209.806 11.08

2.324863

181.667 14.47
178.693

N=70rpm

Udc

111.333 55.42

52.08

inverter
bridge

P(Kw)

108.067 62.23

69.168

380V
power
source

Idc

20

2.628537

206.54

16.38

3.38313

3.573671

202.662 22.66

4.592118

175.164 26.33

4.612772

198.171 29.87

5.91918

171.257 33.25

5.694285

193.068 37.57

7.253385

166.784 40.72

6.791259

187.615 45.85

8.602168

48.57

7.873986

181.842

54.6

9.92856

157.289 56.82

8.937006

175.864 63.58

11.18161

162.13

N=80rpm

152.215 65.22

9.927323

169.565

72.8

12.34436

147.112 73.73

10.84673

163.967 82.19

13.47708

142.213 82.45

11.72492

158.193 91.58

14.48747

137.402 91.37

12.55455

151.953 100.8

15.31684

132.357 99.75

13.20263

145.333 109.2

15.87041

13.6714

138.568 117.13 16.23065

121.539 115.03 13.98074

131.471 124.37 16.35089

126.904 107.73

Udc

Idc

115.7069 121.8

Udc

Idc

P(Kw)

Udc

124.397 130.78 16.26871

Idc

95.03244 157.5

P(Kw)

Udc

14.96761

Idc

P(Kw)

97.8318 160.881 15.73928

91.29996 163.1

14.89102

109.8049 127.98 14.05294

117.398 136.38 16.01088

88.96716 160.069 14.24088

104.072 133.58 13.90205

110.546

15.63114

83.51424 162.05 13.53348

98.64828 138.48 13.66091

103.868 145.72 15.13553

78.5862 163.919 12.88177

80.08794 166.369 13.32415

13.31663

98.0068 149.45 14.64711

73.97892 165.55 12.24721

75.087 167.769 12.59727

87.94656 146.77 12.90783

91.91232 152.83 14.04705

93.25368 142.8

N=70rpm

P(Kw)

14.0931

141.4

N=54rpm

69.72156 166.894 11.63611

83.04768 150.15 12.46961

86.1678 155.87 13.43089

65.69748 168.049 11.0404

78.46956 153.11 12.01455

81.2106 158.32 12.85718

61.8192 169.169 10.45789

74.27052 155.63

11.5588

N=80rpm

55.28736 170.8

72.2002

68.0594 164.03 11.16386

52.22556 171.619 8.962898

62.63568 161.82 10.13564

64.2103 165.43 10.62238

49.63032 172.2

59.36976 163.45 9.703987

60.7403

11.72531

56.30796 164.85 9.282367

57.2994 167.77 9.613063

54.2376 168.82 9.156337

50.7209 167.18 8.479571

51.6132 169.75 8.761341

48.23064 168.12 8.108487

49.0471 170.57 8.365918

Udc

Idc

300.698 0.546

66.42648 169.981 11.29124

62.5482 170.8

10.68323

59.049 171.619 10.13393

8.546341

P(Kw)

Udc

Idc

P(Kw)

0.164181

327.7001

0.6

0.194982

299.123 0.819

0.244982

325.8193

0.89

0.289653

296.207 1.834

0.543244

322.8245

0.644035

4.564

1.340445

319.8269

4.98

1.594017

290.396 8.799

2.555192

315.9486

9.60

3.03437

285.768 14.50

4.144779

310.3207 15.79

4.898413

303.5439 23.57

7.154227

293.7

246.227

70.47972 168.931 11.90621

10.11933

53.39196 165.95 8.860342

Udc

164.85 14.06055

9.443081

66.13488 160.07 10.58614

166.6

N=60rpm

58.37832 170.044 9.926883

76.6325 160.53 12.30189

70.07148 158.03 11.07305

162.4

85.293

Idc

P(Kw)

Udc

Idc

P(Kw)

0.54

0.132716

273.6083

0.56

0.153221

280.082 21.58

6.044445
8.145405

245.1773

0.78

0.192219

272.2961 0.735

0.200138

272.704 29.87

242.3488

1.68

0.407146

269.6134 1.694

0.456725

264.598

39.2

10.37224

285.9021

42.5

12.15198

49.12

12.56709

275.6961 53.12

14.64388

265.044

17.05399

295.42

32.52

9.60558

240.4825

4.05

0.972992

267.5576 4.291

1.14809

255.85

238.3538

7.62

1.815303

264.5104 8.169

2.160785

246.606 59.62

14.70241

3.49977

237.158 70.35

16.68408

254.7797 75.61

19.26491

228.206 81.67

18.63737

244.9148 87.64

21.46434

93.1

20.40712

233.8515 99.38

23.23993

235.2629 12.48

260.807

2.936316

13.42

230.8889 18.32

4.229653

255.7915 19.83

5.072602

226.3982 25.32

5.732177

249.9012 27.53

6.88003

219.196

209.165 103.79 21.70899

220.5079 33.25

7.331888

243.0778 36.13

8.783372

214.2677 41.77

8.949747

235.3037 45.45

10.69479

207.9108 50.87

227.3605 55.23

10.57621

198.326 113.63 22.53597

12.55712

186.974 122.62 22.92656

175.777 130.43

N=100rpm

N=90rpm

N=66rpm

22.9267

64.34

221.7035 110.06 24.40091

N=72rpm

208.7739 119.76 25.00193

197.0341 127.59 25.13939
184.0871 135.1

24.87016

200.8249 60.32

12.11356

219.4582 65.33

14.33742

193.5349 70.12

13.57048

210.9434 75.78

15.98424

164.375 137.43 22.59021

171.5774 141.52 24.28147

153.323 142.33 21.82266

159.0095

147

23.37439

186.4199 80.15

14.94155

203.3035

86.8

17.64675

179.8589

16.24126

195.197

97.3

18.99267

142.826 148.05 21.14534

147.6079 151.67 22.38755

136.8187 155.52 21.27791
126.9043 158.78 20.14999

90.3

172.6564 100.1

17.2829

185.9825 107.22 19.94086

132.795 152.37 20.23379

164.4916 109.32

17.98205

176.2139 116.32 20.49702

123.551 155.87 19.25776

166.5619 124.43 20.72447

114.803 158.9

18.24218

106.871 161.47 17.25642

156.5017 117.72

18.42323

147.9578 125.18

18.52151

156.6767 131.72

139.1807 131.95

18.36489

146.8789 138.02 20.27208

99.6397 163.57 16.29797

137.3436 143.45 19.70208

92.8163 165.5

86.5177 166.95 14.44413

130.7826 137.9

18.03492

20.6373

15.36119

123.026 143.03

17.59654

128.479

114.9779 147.58

16.96855

120.0517 152.13 18.26359

81.0531 168.35

75.991 169.52 12.88191

136.5

17.53738

107.717 151.43

16.3117

112.0036 155.63 17.43123

101.1269 154.58

15.63229

104.7427 158.43 16.59449

13.6453

117.7189 161.47 19.00796

109.4666 163.8

17.93064

101.7101 165.64 16.84736

94.65336 167.3

15.83551

88.23816 168.58 14.87528

82.61028 169.83 14.03003
77.15736 170.8

13.17848

71.5878 170.57 12.21066

72.34596 171.62 12.41594

67.0972 171.33 11.49542

67.88448 172.32 11.69779

63.1897 172.08 10.87375

The maximum power under

different speed

Conclusion:
1.From the above data and graphics it can be observed
that the generator output power at each speed will be a
maximum , when the power reach the maximum, it will

DC bus
voltageV

Speedrpm
48

Maximum output
powerkW

79.3

we can see that the second output power curve of the same

9.674

60

96.02

11.86

72

115.7069

14.0931

gradually decline, and finally tend to zero.

2.Through the comparison of the first and the second sets,
rotational speed is lower than the first one.
3. Connec t the measured maximum points of several
rotational speeds in the maximum power curve, and then

84

131.4708

16.35089

make a quadratic fit by using a computer and forward and

96

147.9578

18.522

backed extend respectively, the maximum power curve of

108

166.5619

20.724

different speed can be re ached. Seen from the f it curve formula,

120

175.7765

22.7267

132

197.0341

25.1394

the quadratic coefficient of y 0.00002 * x 2 0.1872 x 0.7367

is very small, so under the permission of the generator
rotational speed, the maximum output power and the speed
are the linear relationship.

According to the above data the

maximum power trends obtained
at each speed, as shown below:

5.Voltage regulation rate test

The generator is no-load, and adjusted its speed to a
specified value, and change load on the condition of rated
power, the generator voltage regulated rate formula from
no-load to rated current is as followed:

20kW Generator Power to

30

25

P/W

20

n=48
n=60
n=72
n=84
n=96
n=108
n=120
n=132

15
10
5

Note

U 0 UN
100%
UN

U0 output voltage when no-loaded, at rated speedV

UN the voltage when it is at rated loadV

0
0

50

100

150

200

250

300

350

1st and 2nd sets power curve Comparison

Conclusion
the measured no-load voltage U 0 at rated rotational
speed n=60 is 573Vthe voltage of rated load is 318V
calculated voltage regulation rate is about 80.

Rotate Speed-Maximum Power Trend

6.Three-phase stability short-circuit test

2

Y=-2E-05x +0.1872x+0.7367

When measure the three - phase stability short - circuit

36

performance , use low - impedance conductor to make

30

the end of the wire short reliably, as close as possible to

24

the armature winding.

18

Gradually increase the frequency of converter and meter

12

t he output c u r r e n t value of g e ne ra tor only when i t

stabilized, can we get the stability short-circu it

0
0

20

40

60

80

100

120

140

The rotate speed (rpm)

Data recorded in the

following table:

NO-load test
First no -load test

No-load test after short test

540
480

Generator speed
48

Generator
phase current
144.375

420
360
300
240

60

144.75

72

144.8775

120

84

144.9975

60

96

144.9975

108

145.2525

120

145.125

132

145.125

180

0
0

20

40

60

80

100

120

140

Generator speed(rpm)

Conclusion:
From the measured data , it can be seen tha t without
exceeding the permitted speed , the maximum stability
short-circuit phase current is approximately 116A.

7.Determination of three-phase stability

short-circuit no-load performance
Experimental method is the same with the previous noload test, and the variation rate of generators no-load
voltage should be less than 2.
Through the data comparison with generator no-load test
before circuit shorting, analyze the demagnetization of
generator magnet.

Generator speed
rpm

Generator output line

voltage UabV

48

73.953

60

92.934

72

111.564

84

130.545

96

149.148

108

167.967

120

185.976

132

204.39

From the figure, we can see that before and after of the
generator short-circuit; the no-load curve is basically the
same! There are no effects on demagnetization.

8.Stator winding withstand voltage test

This test needs some workers of Experiment Station to
assist in this test.
The testing voltage should be power frequency and as close
as possible to sinusoidal waveform. During the whole test,
security measures are necessary, and around the testing
motors, there should be someone monitoring.
While using the power frequency test platform to carry on
the operation, both the tow ends of the winding should be
shorted and the test voltage is applied on it at the same
time, meanwhile the other windings the test don't refer
and some embedded thermometric element should be made
electrical connections with the reliably grounded core or
motor housing . If the n e u t r a l p oi n t o f t h r e e - phrase
windings is not d i s t i n g u i s hed easily, the three - phrase
windings should be applied the voltage at the same time.
A large resistor should be in series connection in order to
prevent dielectric breakdown.
When testing, the applied voltage should start with less
than half of the testing peak voltage value (start with 480V),
then evenly increase to the full value evenly or by stages
which are not permitted to exceed 5% of the full value(60V
to 1200V this time) ,and the increase time should not less
than 10 second, keep 1min when it reach the peak.
After the test, voltage should be dropped evenly, and the
power should not be shutoff before the voltage decline to
one-third.
At all time, on some abnor m al phenomena such as the
needle of voltmeter runs wild, the showing value of the
ammeter has a sharply increase, the insulation materials
began to smoke, or some noise be heard and so on, you
s h o u l d dec l i ne the v ol t a g e an d sh u t d o w n the p o w e r
immediately.
In the course of acceptance check, the full value withstand
voltage test upon windings should no be enforced a second
time. But if it is insisted , the windings should be further
dried, and test voltage should be 80 of the full voltage.

Conclusion

Data recorded in the

following table:
Measurements

the data show that : basically The data of the three tests
is consistent to each other, so we can safely come to the
conclusion that the short-circuit and the withstand voltage
tests have not changed magnetic flux density neither.

VoltageV CurrentmA

Time(min)

Three-phase
windings to
motor housing

1200

0.01

AB phase

1200

2.03

AB phase

1200

2.14

AB phase

1200

1.82

Conclusion:
Pass the withstand voltage test!

9.The no-load performance measurement

after withstand voltage test
The experimental method is the same as the two previous
no-load tests , and the variation rate of test voltage should
be less than 2.
Through the data comprised with the no - load test of the
generator before shorted, the demagnetization of generator
magnet, should be analyzed.

Generator speed(rpm)

Generator output line

voltage Uab(V)

48

84.5784

60

105.9984

72

127.1124

84

148.0122

96

168.9426

108

190.0872

120

211.0482

132

232.101

NO-load test
First no -load test

No-load test after short test

No-load test after Voltage withstand test

270
240
210
180
150
120

90
60
30
0
0

50

100

150

Rotate speed(rpm)

Comparison of the three no-load tests