ALTERNATORS

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OUTLINE
1. Main Principles of Alternators
2. Main Parts of Alternators
3. Excitation System
4. Alternator Models and Codes (Marelli & Stamford)
5. Technical Specifications of Alternators
6. Voltage and Frequency
7. Three-phase Operation and Power Calculations
8. Single-phase Operation and Power Calculations
9. Power Modes of Operation
10. Class of Insulation
11. Class of Protection (IP Code)
12. Bearings
13. Troubleshooting

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1. Main Principles of Alternators

Mechanical Coupling Electrical

System Area System

Block Diagram of a Basic Electromechanical System

Alternators are rotational electrical

machines.

Alternators are electromagnetic

devices that convert mechanical
energy to AC electrical energy.

Overview of a Diesel Generator

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 2. Main Parts of Alternators
Rotating poles of a brushless alternator are located on the rotor and also named as Main Rotor.
Excitation rotor windings and rotational diodes are also located on the shaft besides main rotor.
Three-phased voltage induced at the excitation rotor is rectified via the diodes and delivered to the main
rotor.
Excitation stator has stationary poles.
Automatic Voltage Regulator (AVR) controls the current delivered to the excitation stator. Thereby the
excitation rotor which feeds the main rotor is controlled also.

Voltage regulator controls the voltage

generated by alternator. When the
voltage at the output of a generator is
lower than the desired level, it delivers
more current to the excitation stator so
that the magnetic field strength rises and
the voltage at the output of the generator
is fixed.

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2. Main Parts of Alternators
AVR

Rotating
diodes

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2. Main Parts of Alternators
Main Stator
Stator is constructed in layers to reduce Eddy-Current losses and winding temperature.
The voltage at the output of the alternator is dependent on the winding type, stator length,
rotation speed and the magnetic field of the rotor.
The current at the output of the alternator is dependent on the cross-sectional area of the
copper cables used in the windings.

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2. Main Parts of Alternators
Main Rotor
Rotor is the part that is rotated by the engine in order to generate electricity.
Rotor has parallel connected windings.
All single winding connection is just the opposite of the previous one. Therefore it is
obtained that the poles of the magnet (N or S) change repeatedly.

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2. Main Parts of Alternators
Rotating Diodes
There are 2 rotating diodes per phase.
They are located at the center of excitation rotors outer
surface.
2 Aluminum plates are the output terminals of rotating
diode and used for supplying current to the main rotor
continuously.

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2. Main Parts of Alternators
Rotating Diodes

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2. Main Parts of Alternators

Surge Suppressor - Varistor

Varistors are used to absorb instantaneous

voltage level changes (rise or drop) which may
occur due to load changes.
Incorrectly synchronized parallel generators or
short circuit occurrence at load may cause
breakdowns.

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2. Main Parts of Alternators
PMG (Permanent Magnet Generator)

It is an independent
power source with an
8-pole rotor.
It generates 3-phase
170-220 Vac and 100
Hz electricity at 1500
rpm and feeds the
AVR.

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2. Main Parts of Alternators

PMG (Permanent Magnet Generator)

PMG, provides power for AVR

independent from load changes.
Signal noise suppression is better in
usage of PMG, rather than stator fed
excitation systems.

It provides the generator extra

overloading capacity.

It supplies energy from generator

windings in some special cases.

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2. Main Parts of Alternators
Output Terminal

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 2. Main Parts of Alternators
Automatic Voltage Regulator (AVR)

Voltage regulators are used to avoid voltage drops and keep the
voltage stable while the generator is loaded. It gets reference
voltage levels from the output of the generator and compares
them with the desired level. Voltage level at the output of the
generator is kept at a desired level by the voltage regulator. It
informs the excitation system about the output or desired voltage
levels, so it assists the excitation system for voltage drop or rise.

In general a voltage generator is asked to provide;

Stable excitation voltage while working with fixed load.
Shortest response time on instantaneous load changes.
DC excitation voltage at a desired level in occurrence of instantaneous load changes or overloads.

Voltage level will decrease if the excitation voltage is kept constant during instantaneous load changes.
This voltage drop is because of the load current causing voltage drop on the inner reactance of generator.
Generator reactance and (partially) the reactive power drawn by the load are the main factors
that affect the level of voltage drop.

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2. Main Parts of Alternators
Automatic Voltage Regulator (AVR)

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2. Main Parts of Alternators
Automatic Voltage Regulator (AVR)

MX341
AS480 (UC22-HC5 opt.)
(P0/P1 std) (P7 std)

MX321
AS440 (UC22-HC5 opt.)
(UC22-HC5 std) (P7 opt.)
(HC6 std.)

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2. Main Parts of Alternators
Automatic Voltage Regulator (AVR)
Setting Voltage Level: Potentiometer shall be turned clockwise to increase voltage level and
counter clockwise to decrease the voltage level.

VOLTAGE
VOLTAGE

VOLTS

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2. Main Parts of Alternators
Automatic Voltage Regulator (AVR)

Setting Stability:
Stability is the response time of the AVR while balancing the output voltage.

Its settings should be done this way;

First operate the generator with no load for some time.

Turn the stability potentiometer in counter clockwise direction
till the voltage gets unstable.

Then turn it clockwise till the voltage gets stable.

Check out the nominal voltage settings

STABILITY
Test the generator on load.

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 3. Excitation System
After flowing through the auxiliary windings at the main stator, the current is rectified in a regulator.
After regulation, pole windings in excitation stator are supplied by this DC power. When these poles are
supplied with power, magnetic flux is generated. This magnetic flux causes three-phase AC power on
excitation rotor windings, and finally this AC power is rectified by the help of a rotational diode rectifier
and delivered to the main rotor in DC form.

EXCITER EXCITER MAIN

STATOR ROTOR ROTOR
U1
U

~ + V1
~ V
~ -
W1
ROTATING W
RECTIFIER

IN (SUPPLY)
OUT (+) AUXILIARY WINDING
AVR
OUT (-) IN (SENSING)

SETTING
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 POWER

3. Excitation System SUPPLY

A
X+ (F1) EXCITATION
V
XX- (F2)
TRIP CIRCUIT
R
Main Stator
Excitation
Rotor & Stator

Bearing

Main Rotor
Main Rotor Shaft

Rectifier Fan

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3. Excitation System

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4. Explanation for Model Names
of Alternators (Marelli)
Let us explain this with an example; MJB 400 MA4

MJB It indicates that the generator set has low-voltage ratings.

400 It indicates the length of the chassis.

MA It is another dimensional parameter.

4 It indicates the number of poles.

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 P80
4. Explanation for Model
- Reference
Names of Alternators
(Stamford)

KVA rating @ 50 Hz
KVA rating @ 60 Hz
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5. Technical Data on Generators
Excitation System: Brushless, self excited with AVR (Automatic Voltage Regulator).

Nominal Voltage : 230/400VAC@50 Hz or 254/440VAC@60 Hz

Speed: 1500 rpm@50 Hz or 1800rpm@60 Hz

Power Factor (cos): 0,8 for three-phase or 1,0 for single phase.

Number of Phases: Single phase or three phase.

Frequency: 50 Hz or 60 Hz.

Class of insulation: H

IP (Ingress Protection) Code: IP23

Number of Poles: 4

Number of Bearings: Single

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 6. Voltage and Frequency
Generators may generate voltage at both 50 and 60 Hz frequency.
They may have 6 or 12 output terminals depending on the alternator model.

For example, generators between MJB160SA4 and MJB355MA4 standardly have 12 terminals.
Generators with higher ratings than MJB355MB4 standardly have 6 terminals.

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6. Voltage and Frequency

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6. Voltage and Frequency
Voltage rating of the generator may differ depending on applications generally.

In emergency or standby applications, output voltage of the generator is set to be at the

same level with the load connected to the generator.

However in prime or base load applications, it is set to be at medium voltage level (higher
than 600V) and also with high frequency.

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7. Three-phase operation and power calculations on 3-phase

A diagram showing a three-phase circuit

There is a 4th line called neutral line in three phase synchronous generators applications.
This neutral line is a protection against unbalanced loading conditions at both (supply or load) sides.
Voltage and current in three phase systems, are classified into two; line-to-neutral voltage/current (VLN / ILN) and
line-to-line voltage/current (VLL / ILL).
Three-phase synchronous generators has a power factor equal to 0,8.

S : Complex (Apparent) Power

P : Active Power
Q : Reactive Power

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7. Three-phase operation and power calculations on 3-phase

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7. Single-phase operation and power calculations on 1-phase
Three-phase generators can operate just line single phase generators thanks to zigzag
connection.
But if a 3-phase generator is turned into a single phase generator by using zigzag connection,
then the efficiency of generator decreases with a %33 percentage and this leads to a %66
efficiency.
(Voltage: 220-240V@50 Hz or 220-240V@60 Hz)

Zigzag
Connection

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 9. Power Modes of Operation
Standby Power Mode: Generators is loaded with a varying load in this mode and will work a limited number of
times. It may operate up to 500 hours a year under 70% loading conditions. It is used as a backup power source
for mains failure occasions. No overloading is possible in this power mode.

Continuous Power Mode: Generators are the only power sources in this mode so they are always online under
suitable operating conditions. As generators are the only and primary power sources in this mode, this is the
operation mode that a generator gives its best and reaches its maximum in terms of power generation.
Generators can operate for an unlimited time period but can not be overloaded.

Overloading: Maximum overloading percentage and time limitations are as follows;

%110 for 60 minutes,

%115 for 10 minutes,
%130 for 4 minutes,
%150 for 2 minutes.

NOTE: This overloading conditions can be applied

sometimes but not always. Also generators must
operate at nominal or less load for a while (1 hours min.)
after overloading.

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 10. Class of Isolation

Generators are classified in class H in terms of

insulation. (Note that isolation class for MV and
HV applications is F)

Generators have NEMA, F or H class

winding isolation.

H class isolation is designed for higher

temperatures than F class applications.

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11.
IPClass of Protection
(Ingress Protection) Code of an electrical product, numerically indicates the protection / safety level of its
outer body.

Generators are classified in IP23 protection class standardly.

First number in IP code indicates the protection of an electrical equipment against solid objects and classified
as follows;

1st
Definition Description
Char.
0 Unprotected -

1 Protection against objects with diameter 50 mm or higher. Objects having diameter more than 50mm cannot pass through.1

2 Protection against objects with diameter 12,5 mm or higher. Objects having diameter more than 12,5mm cannot pass through.1

3 Protection against objects with diameter 2,5 mm or higher. Objects having diameter more than 2,5mm cannot pass through.1

4 Protection against objects with diameter 1 mm or higher. Objects having diameter more than 1mm cannot pass through.1

5 Protection against dust. Dust particles may pass but not at a disturbing level.

6 Dust-proof. Even no dust can pass through.

1 Diameter of any solid object is not suitable for passage through any hole or gap on the body.

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11. Class of Protection
Second number in IP code indicates the protection of an electrical equipment against liquid and classified as
follows;

1st
Definition Description
Char.
0 Unprotected -

1 Protection against vertical water drops. Vertical water drops cannot pass in.

Protection against vertical water drops despite being 15o Vertical water drops cannot pass in even if being angled 15o with
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angled horizontally the horizontal axis in both directions.

3 Protection against water sprays. Water sprays with an angle of 60o in any direction, cannot pass in.

4 Protection against water splashes. Water splashes coming from any direction, cannot pass in.

5 Protection against water jets. Water splashes coming from any direction, cannot pass in.

6 Protection against strong water jets. Any strong water jet coming from any direction, cannot pass in.

Sinking up to 1 meter temporarily may be possible on standard

7 Protection against sinking into water temporarily.
ambient, time and pressure conditions

Suitability for operation underwater permanently, of course in the

8 Protection against sinking into water permanently.
environmental conditions declared by manufacturer.

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12. Bearings

Big-sized roller bearings are used in

alternators.

Over-speeding limit is up to 1,5 times

the nominal speed. (in 50 Hz)

Alternators have single (main) bearing

standardly.

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Troubleshooting

13. Troubleshooting
Following equipment may be helpful for you during troubleshooting, maintenance or repair;

Multi meter,
Tachometer/speedometer or frequency meter,
Megger (for isolation test),
Clamp ammeter,
Kelvin Bridge (for measuring too small resistances)

MEASURING RESISTANCE

One and most basic technique for troubleshooting is to make some measurements on electrical or
electronic components and compare these measurements with the catalog values.

Multi meter can make accurate measurements on 10 or more resistances, but its accuracy is not
enough for measurements between 0.5 and 5 .

So more precise measurement devices or other measurement techniques like Kelvin Bridge must be
used for measurements in this (0,5-5 ) range.

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13. Troubleshooting
DIODE TEST

Two different resistance values must be measured on a diode; one measurement in forward direction,
one in reverse direction. These measurements can be made with a multi meter.

There is a notation scratch on the anode side of a diode. Measurements in forward (Figure A) and
reverse (Figure B) direction are made according to this scratch, as shown in figure below.

Resistance value measured in forward direction must be between 20-100 , it may vary depending on the
type of diode or impedance of the measuring device.

100 k or higher resistance must be measured in reverse direction.

If any short circuit or open circuit is detected during these measurements, then the diode is faulty.
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13. Troubleshooting
GROUND INSULATION
Electronic devices line AVR or rotor diodes must be disconnected before starting isolation test.

Insulation resistance between the body of alternator and conductors, is tested using MEGGER.

MEGGER applies 500-1000V voltage to the insulation between body and copper windings. Current leakages
occur due to this high voltage and MEGGER shows a resistance value in mega ohms by measuring this
leakage current.

This value read with MEGGER must be higher than 100 M in low-voltage generator sets,
if it is not then the windings must be cleaned, dried or renewed till 100 M is measured.
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13. Troubleshooting
EXCITATION MANUALLY:

Alternator windings and excitation system may be tested using this technique.

First, anode (+) and cathode (-) connections of AVR (coming from excitation system) must be removed.

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13. Troubleshooting
EXCITATION MANUALLY:

Make the connections between battery and excitation system as shown in figure. (Supply battery voltage
directly to the terminals of excitation stator.)

Connect a forward biased diode on line connected to the anode of the battery.

Disconnect any load, start the engine and let it run till it reaches its nominal speed.

If 25-40V voltage (depending on the

model of the alternator) voltage is
generated on the alternator with only
battery supply, then it means there is
not any problem with excitation
system.

So excitation rotor, excitation stator,

power diodes and varistors (surge
suppressors) are just fine.

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41 22.11.2016