WHAT IS AN ALTERNATOR

A MACHINE CONVERT
MECHANICAL ENERGY
TO ELECTRICAL
ENERGY
 HOW ALTERNATOR WORKS

 Alternators generate electricity by the

same principle as DC generators,
namely, when the magnetic field
around a conductor changes, a current
is induced in the conductor.
HOW ALTERNATOR WORKS

Typically, 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.
 TYPES OF ALTERNATORS

 BRUSH  BRUSHLESS
IDENTIFYING DIFFERENCES
BETWEEN ALTERNATORS
BRUSH ALTERNATOR
BRUSH ALTERNATOR
COMPONENTS OF BRUSH ALTERNATOR

SLIP RINGS
BRUSH HOLDERS
 BRUSH HOLDERS

Use to hold the

brushes firmly to the
slip ring
CARBON BRUSHES
 CARBON BRUSHES

Brushes are critical for the operation

of the revolving electrical machinery.
This graphite component helps to
carry current while ensuring contact
between the static and rotating parts
of the motor.
 COMPONENTS OF BRUSH
ALTERNATOR

SLIP
RING

Brush holder
 CARBON BRUSHES
SLIP RINGS

BRUSH HOLDER

CARBON
BRUSHES
SLIP RING
BRUSHLESS ALTERNATOR
COMPONENTS OF BRUSHLESS
ALTERNATOR
Main Field or Main Magnetic Winding (Rotor)

Main Armature winding (stator).

Exciter rotor (exciter armature)

Exciter field winding

Rotating rectifier

AVR-Automatic Voltage Regulator

 TERMINOLOGY
The stationary part of a motor or alternator
is called the stator and the rotating part is
called the rotor. The coils of wire that are
used to produce a magnetic field are called
the field and the coils that produce the
power are
called the armature.
STATOR WINDINGS
MAIN ROTOR FEILD
 CONSTRUCTION

A brushless alternator is composed of two

alternators built end-to-end on one shaft.
Smaller brushless alternators may look like
one unit but the two parts are readily
identifiable on the large versions. The larger
of the two sections is the main alternator and
the smaller one is the exciter. The exciter has
stationary field coils and a rotating armature
(power coils)..
EXCITER ROTOR
 EXCITER FIELD
A typical rotating-field AC
generator consists of an Wound exciter field
alternator and a smaller DC
generator built into a single unit.
The output of the alternator
section supplies alternating
voltage to the load. The only
purpose for the dc exciter
generator is to supply the direct
current required to maintain the
alternator field. This dc generator
is referred to as the exciter.
ROTATING RECTIFIER
 CONSTRUCTION Contd..

The main alternator uses the opposite

configuration with a rotating field and
stationary armature. A bridge rectifier, called
the rotating rectifier assembly, is mounted on
a plate attached to the rotor. Neither brushes
nor slip rings are used, which reduces the
number of wearing parts
SALIENT POLE ALTERNATOR
FOUR POLE TURBO ALTERNATOR

The rotors are thus

made from steel
forging, or in some
cases from thick steel
discs bolted together.
STRUCTURAL VIEW OF AN
EXPLODED ALTERNATOR

(STATIONARY)

(STATIONARY)
BRUSHLESS ALTERNATOR
PARTS DESCRIPTION
PARTS DESCRIPTION
BRUSHLESS ALTERNATOR SCHEME
USING SHAFT MOUNTED DIODES
 CONTROL SYSTEM

Varying the amount of current through the

stationary exciter field coils varies the 3-
phase output from the exciter. This output is
rectified by a rotating rectifier assembly,
mounted on the rotor, and the resultant DC
supplies the rotating field of the main
alternator and hence alternator output. The
result of all this is that a small DC exciter
current indirectly controls the output of the
main alternator.
 SCHEMATIC DIAGRAM FOR
EXCITATION
EXCITER ROTOR CIRCUIT
A C B
4 POLE ROTOR WINDING
P1 P2 P3 P4
X
+ XX
D1 D2 D3

VARISTOR

D6 D5 D4

-
6 DIODE RECTIFIER
CONTROLING THE OUTPUT
EXCITATION FIELD WINDINGS
P1 P2 P3 P4 P5 P6 P7 P8

X XX

VAC X XX VAC(N) FROM POWER

WINDING
AVR
 AUTOMATIC VOLTAGE
REGULATOR (AVR)
An automatic voltage control device controls
the field current to keep output voltage
constant
AVR-AUTOMATIC VOLTAGE
REGULATOR

SERIES 6
R230
HAND MADE

BT153
SYNCHRONOUS SPEEDS

The output frequency of an alternator

depends on the number of poles and the
rotational speed. The speed
corresponding to a particular frequency is
called the synchronous speed for that
frequency. This table gives some examples
SYNCHRONOUS SPEEDS CONT..
More generally, one cycle of alternating
current is produced each time a pair of field
poles passes over a point on the stationary
winding. The relation between speed and
frequency is N = 120f / P , where f is the
frequency in Hz (cycles per second). P is the
number of poles (2,4,6...) and N is the
rotational speed in Revolution per minute
(RPM).
FAULT DIAGNOSIS TABLE
FOR GENERATORS
 NO VOLTAGE

S/N CAUSE CHECK AND REMEDY

1 Ruptured AVR Fuse Check and replace if necessary with identical type
With regulator disconnected and machine stationary, Flash
Loss of Residual exciter field using a 12volts battery across field terminals X
2
Magnetism and XX. Correction of polarity is important. Reconnect field
leads.
Exciter field winding Check continuity of shunt-field and leads to regulator.
3
failure Check winding resistance.
Exciter rotor winding Disconnect A.C. Input Leads to diode bridge and, check
4
failure winding resistance
5 Rectifier fault Check rectifier and replace if faulty
6 Alternator field winding Disconnect supply leads from diode and check resistance.

Main stator winding Check resistance and return to factory for repair of fault
7
failure
Check with relevant diagram, particular refrence shorts
8 External winding failure
and earths fault. Repair as necessary.
Check and correct connection to supply. If Ok, replace
9 Regulator
regulator unit and return suspected one
10 Generator Load Check load and remove excess
 LOW VOLTAGE
S/N CAUSE CHECK AND REMEDY
Reduce load. With 3phase generators, the load on each phase should be
1 Excessive Load as evenly balanced as possible and not exceed the rated current for each
phase.
2 Low speed Check engine for malfunction or system for over load
3 Insufficient excitation Check regulator (AVR). Replace if faulty.
4 Line Loss Increase size of line cable
Make a better connection electrically and mechanically.
High Resistance
5 connections
(Connections will be Hot)

Test field coils for possible short circuit by checking resistance with an
Alternator field winding
6 Ohmmeter or resistance bridge. If fault returns back, go to a rewinder
short circuit
for a repair.
Reduce induction (motor) load. Some A.C motors draws approximately
the same current regardless of load. Do not use motors of larger
7 Low power factor horsepower rating than is necessary to carry the mechanical load.
 HIGH VOLTAGE

S/N CAUSE CHECK AND REMEDY

1 Excessive speed Check engine for malfunction
Voltage regulator Check with new regulator (AVR)
2
defective replace if necessary.
Check with particular reference to
3 External winding connection and continuity of
sensing leads to regulator
 FLUCTUATING VOLTAGE
S/N CAUSE
1 Irregular speed of engine
2 Lose terminal or load connection
3 Voltage regulator unstable
4 Intermittent short in exciter field
Defective bearing causing
5
uneven air gap
CHECK AND REMEDY
Check engine for malfunction or load for
fluctuation. Stabilize load. The addition of a lamp
load (resistance load) may compensate partially
for load changes caused by intermittent motor
operation. Do not over load.
Make a better connection mechanically and
electrically.
Check regulator. Replace if faculty.
Test field coils possible short by checking
resistance with an ohmmeter or resistance
bridge. Take it to the workshop for repair if field
coil is shorted.
Replace worn-out with new ones.
 OVER HEATING
S/N CAUSE
1 Generator overload
2 Charred ventilating screens
High room temperature or
3
insufficient air circulation
4 Operating with excessive voltage connection. Adjust voltage as described in
5 Low power factor
6 Unbalanced load
7 Dry bearing
CHECK AND REMEDY
Reduce load. Check with ammeter and compare
with name plate rating.
Cleaning air passage
Improve ventilation provide cross ventilation
Check voltage drop in distribution lines and
voltage deviation instructions
Reduce inductive loads.
The load on each line should be as evenly
balanced as possible and should not exceed the
rated current on each phase.
Replace with new ones.
 MECHANICAL NOISE

S/N CAUSE CHECK AND REMEDY

1 Defective bearing Replace bearing

Replace Bad bearing. Bent shaft,

Rotor scrubbing on
2 loose end belt and tighten.
stator

Tighten or align.
Loose or misaligned
3
coupling
GENERATOR FRAME PRODUCES
SHOCK WHEN TOUCHED:

S/N CAUSE CHECK AND REMEDY

1 Static charge Ground generator frame

Grounded Return to workshop for
2 armature or repair
field coil
CONTROL COMPONENTS
WATER TEMPERATURE GUAGE FOR
TEMPERATURE CONTROL IN
RADIATORS
WATER TEMPERATURE SWITCH FOR
TEMPERATURE CONTROL IN
RADIATORS
OIL SWITCHES
OIL GUAGE
AMPERE METER
METER PANEL
FUEL SOLENOID
MAGNETIC PICKUP IN GENERATOR
ACTUATORS
CONTROL PANEL
SLIP RINGS AND BRUSHES
STATOR
KICK STARTER
24V DC BATTERY
INJECTOR PUMP
ELECTRICAL COMPONENT
ELECTRICAL COMPONENT