Alternators

Alternators 2
To Generate Current we Need:

Magnetic Field N

Conductor +

Movement
-
S
Alternators 3
 Rotor
Magnetic field
N

S
Stator
Coil

Alternators 4
 V
S o
N l
t
N
S
N

Time
S

a
g
N
S e

Alternators 5
+
V Peak
o Voltage
RMS
l (0.707 Peak value)
t
a Time
g
e
Amplitude

Cycle

Alternators 6
N
V
o
l
t
S a Time
g
e

Alternators 7
 V
o
2 pole rotor
l sine wave
N t
a Time
g
N

S
e

S 4 pole rotor
sine wave

Number of poles X RPM

Frequency = = Hz
2 X 60

Alternators 8
T0 T1 T2 T3

L4
L1

Field L2
L3 Armature
Diode

Field
Stator

Alternators 9
Alternators 10
Alternator Parts List
No. Nbr. Description No. Nbr. Description
1 1 Stator assembly 107 1 Support diode assembly
4 1 Rotor assembly 124 1 Terminal plate
15 1 Fan 198 1 Regulator(AVR)
16 6 Fan fixing screw 207 1 Rubber
28 1 Earth terminal 290 1 Housing
30 1 DE flange 291 1 Adaptation shaft
33 1 Air outlet louvre 292 1 Rotor magnets
36 1 N.D.E.bracket 293 1 Stator
37 4 Tie rod 294 2 Fixing screw
41 1 D.E.terminal box 295 1 Tie rod
47 1 N.D.E.terminal box 296 1 Washer & nut
48 1 Terminal box lid 297 1 End plate
49 20 Terminal box fixing screw 320 1 Hub
51 1 Air intake louvre 322 1 Coupling disc
59 3 Inspection door 323 Fixing screw
70 1 NDE bearing 324 1 Clamping washer
79 1 Preloading wavy washer 325 Spacer shim
90 1 Wound exciter field 343 1 Diode bridge assembly
91 4 Field fixing screw 347 1 Surge suppressor Varistor
98 3 Corner plate 349 1 O ring seal
100 1 Exciter armature

Alternators 11
Alternator Labelling

Alternators 12
Alternator Labelling
Genset Alternator
30 KVA LL1014Q
44 KVA LL2014B
50 KVA LL2014D
65 KVA LL2014H
77 KVA LL2014J
100 KVA LL3014B
110 KVA LL3014B
150 KVA LL3014F
175 KVA LL3014H
188 KVA LL3014H
200 KVA LL5014F

Alternators 13
Model Specification

Alternators 14
Generator Set Serial Number

Alternators 15
Generator Set Serial Number

Alternators 16
Label each item:
L1
L2
L3
1) AVR
N
2) EXCITER STATOR

3) EXCITER ROTOR

4) RECTIFIER

5) MAIN STATOR

6) MAIN ROTOR

Alternators 17
Alternator Principle

STATOR
WINDING
ROTOR
WINDING

Alternators 18
Alternator Principle
EXCITER FIELD
RECTIFIERS
STATOR
WINDING

ROTOR
WINDING

DIRECT ALTERNATING
CURRENT CURRENT

Alternators 19
Alternators 20
1. Shunt Principle
EXCITER FIELD (4)
RECTIFIERS (6)
STATOR (2)
WINDING

EXCITER (5)
ROTOR
WINDING
ROTOR

AVR

DIRECT ALTERNATING
CURRENT CURRENT

Alternators 21
2. Shunt + PMG Principle
EXCITER FIELD
P.M.G.
RECTIFIERS
STATOR
WINDING

ROTOR
WINDING

A.V.R.

Alternators 22
PMG
290 Housing
291 Adaptation shaft
292 Rotor magnets
293 Stator
294 Fixing screw
295 Tie rod
296 Washer & nut
297 End plate

Alternators 23
PMG
5 TYPES PMG 1 2000-3000 Series R438
PMG 2 5000-6000 Series R448
PMG 3 7000 Series R448
PMG 4 8000-8100 Series R449
PMG 5 9000-9100 Series R449

ADAPTATION ON A SHUNT MACHINE 2000-3000

- Replacement of R 230A by R 438 LS/A + Support
- Modification of connections (wiring supplied)
- Exciter Field reconnection (series to parr.)
- Mechanical fitting of PMG
>>>>>> Adaptation kit
Alternators 24
PMG

14
X2
Z1 15 PMG
AVR X1
2000-3000 Series 16
Z2
E+
PMG CONNECTION E- 6- 5+
(AVR) EXCITER FIELD

AVR connection for PMG.

Alternators 25
3. AREP Principle EXCITER FIELD
RECTIFIERS
STATOR
WINDING

ROTOR
WINDING

AVR

DIRECT
ALTERNATING
CURRENT
CURRENT

Alternators 26
Auxiliary Winding Principle

H1----Delivers a voltage to the exciter field, proportional to the

output voltage ( wound in on top of the red phase windings of
the main stator). X1,X2

H3----Delivers a voltage to the exciter field, proportional to the

output current ( wound in on top of the blue phase windings of
the main stator). Z1,Z2

Alternators 27
Excitation Systems
SHUNT + PMG AREP SHUNT

High starting High starting

capacity capacity

Short-circuit Short-circuit Self protected

ADVANTAGES capability capability against short circuit

Intrinsic build-up No extra length No extra length

Extra No short- circuit

Specific winding capability
length

High number Low starting

Small added cost
of components capacity
DISADVANTAGES

Added cost Sensitive to

distorting loads if
thyristor controlled

Alternators 28
Overload Characteristic
VOLTAGE (V) SHUNT CHARACTERISTIC
( or auxiliary winding H1/ AREP) AREP/ PMG CHARACTERISTIC

AREP SERIES CHARACTERISTIC

UN
( Auxiliary winding H3/ AREP)
SUSTAINED
VOLTAGE DIP

LOAD %
100% 200% 300%

LOW OVERLOAD HIGH OVERLOAD - SHORT CIRCUIT

Alternators 29
Shunt, AREP or PMG ?
AREP / PMG ADVANTAGES COMPARED WITH SHUNT
The short circuit capability that enables a selective protection in case of overload
or short circuit on an installation

WHEN TO CHOOSE AREP OR PMG ?

Whole installation with several circuits
Power cut forbidden
High rate of distorting loads
Startin 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 of the alternator

Alternators 30
Generator Set Ratings
COP: Continuous Power
• Continuous operation at nominal constant load
• Unlimited number of hours / year
• Cogeneration / Marine...
• Alternator rating S1/ 40°C - class H or F

PRP : Prime Power

• Continuous operation at variable load (average load at 70% of the nominal load)
• Unlimited number of hours/year
• Industry. Public works...
• Alternator rating S1 40°C - Class H
• Load capability

LTP : Limited Time Power – Stand-By

• Maximum rating allowed during 500 H/year (max 300 hours continuous running)
• Alternator rating stand-by duty 27°C

Alternators 31
 Voltage …….. Voltage Regulator
Output Control (Function of… speed + excitation current)

Frequency…. Speed Governor

(Function of… speed + number of poles)

kW …………. Engine kW Rating

Genset Limits
Amps……… Alternator Wires Capability

Alternators 32
Frequency
Speed (min -1) x N (no of poles)
Frequency (Hz) =
120

Main Frequencies:
50 Hz : Europe, Africa, part of Asia, part of South America
60 Hz : North America, part of Asia, part of South Americas.
400Hz : Airports

Alternators 33
Alternator Speed

Speed in Min -1 or R.P.M.

POLE 2P 4P 6P 8P 10P 12P 14P 16P

50 Hz 3000 1500 1000 750 600 500 428 375

60 Hz 3600 1800 1200 900 720 600 514 450

Direction of Rotation

Standard : Clockwise (looking from the drive end)

Alternators 34
Power Factor kW

CAPACITIVE INDUCTIVE

kVA

AR
kV

• kW = Active Power (real)

• kVA = Power (apparent)
• kV AR = Reactive Power (reactive)
• Inductive P.F. = Inductive Load, Isynchronous Motor, Transformer (current lags
the voltage)
• Capacitive P.F. = fluorescent light, capacitor (current leads the voltage)

Alternators 35
 A

1
V

A
Reactive
V power (3)


3 Real power (1)

Pf = cos  = KW/KVA
V

Alternators 36
 KVAR Leading
Engine Limit (KW)
Function of the
maximum fuel to
the engine
The KVA
Circle
800 1000 KW
Diagram
Generator Limit (KVA)
Function of the
maximum current
allowed in the generator
windings

KVAR Lagging

Alternators 37
 KVAR Leading
Engine Limit (KW)
Engine overload
Generator Limit (KVA)

The KVA
Circle
800 1000 KW
Diagram

KVAR Lagging

Genset overload
Alternators 38
Overload

OVERLOAD HIGHER TEMPERATURE RISE

PERMISSIBLE OVERLOADS (NOT DANGEROUS FOR THE ALTERNATOR)

DURATION 1H 30’ 15’ 5’ 2’ 30” 10” 3”

OVERLOAD 10% 11% 14% 25% 50% 100% 200% S.C, 3 PH

Each running with overload must be followed by a running

at the nominal rating during at least 1 hour or 10 minutes without load

Alternators 39
Alternators 40
Composition of a Periodic Signal
 Any periodic signal of frequency "f", whatever its waveform, can be
represented as the sum of:

– a sinusoidal component of frequency f, called the FUNDAMENTAL (h1)

– sinusoidal components with frequencies that are whole multiples of the
fundamental, called the HARMONICS (hn)
– a DC component (if applicable)

 Example :
y( t ) = h 1( t ) + h 3( t )
1.5 1.5 1.5

1 1 1

0.5 0.5 0.5

0 0

-0.5
= -0.5
+ 0

-0.5

-1 -1 -1

-1.5 -1.5
-1.5

Alternators 41
What Are Harmonics?
Harmonic currents can cause an unacceptable disturbance on the supply network and adversely
affect the operation of other electrical equipment including power factor correction capacitors.
All complex waveforms can be resolved into a series of sinusoidal waves of various frequencies,
hence any complex waveform is the sum of a number of odd and even harmonics of lesser or
greater value. The diagram below shows examples of several harmonics compared to the
sinusoidal wave and the resultant wave after distortion.

Alternators 42
Harmonic Filtration

Alternators 43
2/3 Pitch Winding
Note
A 2/3 pitch winding eliminates all triplen harmonics (3, 6, 9, etc)
which create a circulating current in the neutral and distort
the waveform.

When is a 2/3 pitch winding needed ?

A 2/3 pitch winding is generally used for the following reasons :
Single phase loads sensitive to distortion
single phase rectifiers, gas discharge lighting
Paralleling
with other alternators when neutrals are connected
with the main network when neutral is distributed

Alternators 44
Typically a main stator will consist of 9 Full Pitch
winding entries at full pitch, therefore
there should be at 2/3 pitch 2/3 Pitch

Phase Winding Entry

This is where a phase

winding will enter the main
stator then exit at 2/3 pitch

Alternators 45
Voltage
12 WIRE RECONNECTABLE MACHINE
EXAMPLE: STANDARD WINDING N° 6 - 3 PHASE/ 2/3 PITCH.

SERIES STAR CONNECTION PARALLEL STAR CONNECTION

Alternators 46
Voltage
12 WIRE RECONNECTABLE MACHINE
EXAMPLE: STANDARD WINDING N° 6 - 3 PHASE/ 2/3 PITCH.

SERIES DELTA CONNECTION PARALLEL DELTA CONNECTION

Alternators 47
Voltage
12 WIRE RECONNECTABLE MACHINE
EXAMPLE: STANDARD WINDING N° 6 - SINGLE PHASE

(FF) CONNECTION CONNECTION ZIG - ZAG (G)

( NOT RECOMMENDED)

Alternators 48
Alternators 49
Mechanical Defects

Alternators 50
Electrical Defects

Alternators 51
Electrical Defects

Alternators 52
Fault Finding on the Main Stator

L1 L1
100 120
L2 80 140 L2 120 120

L3 L3

L1
70
L2 100
90
L3

Alternators 53
Fault Finding the Exciter Stator & AVR

DIRECT ALTERNATING
CURRENT CURRENT

Alternators 54
Testing the Diodes

MULTIMETER MULTIMETER

MORE THAN LESS THAN

10,000 OHMS 100 OHMS

Alternators 55
Fault Finding- Testing the Resistance
of the Main Rotor using a 6V battery.

AVO meter on 10amp +

range or DC ammeter.

6V

Rotor Resistance = 6
AMPS

Alternators 56
Insulation Test

1.Minimum acceptable value of insulation to earth is one Megohm

2.The AVR MUST be disconnected before meggering the windings

3.Megger the: Main stator

Main rotor
Exciter stator
Exciter rotor

Meggering is only necessary if the generator has become wet or

has not been used for a long time
Use a 500V DC insulation tester

Alternators 57