Alternator Basics PDF

NEWAGE PRODUCT TRAINING

WHAT IS ELECTRICITY ?
 Electricity is a NATURAL form of ENERGY, e.g, LIGHTENING,

STATIC CHARGE.
 ALL forms of MATTER in the Universe, (solid, liquid or gas), are

made of ATOMS. The electrical force in the atom is called the
ELECTRO-MAGNETIC FORCE. This force holds ELECTRONS in
orbit, around the NUCLEUS of the ATOM.
 An electrical CHARGE, (or POTENTIAL DIFFERENCE),measured

in VOLTS), is created when ELECTRONS are stripped from ATOMS.
 This CHARGE, (or VOLTAGE), provides the ‘pressure’ in an

electrical circuit, causing ELECTRONS to flow in conductors.
Lets take a closer look at the ATOM

WHAT IS ELECTRICITY ? - THE ATOM
AA
HYDROGEN
COPPER ATOM
ATOM
ELECTRON NUCLEUS
(NEGATIVE CHARGE) (POSITIVE CHARGE)
VALENCE OR
ELECTROMAGNETIC CONDUCTIVE BAND
FORCE
2
ELECTRON ‘SHELL’
8
18
1
 The ELECTRO MAGNETIC FORCE is second only in strength to the NUCLEAR
FORCE.
 In a COPPER CONDUCTOR, the ELECTRON in the VALENCE band is FREE to flow
from atom to atom, when attracted by a POTENTIAL DIFFERENCE or CHARGE.

WHAT IS ELECTRICITY? - VOLTAGE AND CURRENT
A COPPER CONDUCTOR
+ ELECTRON
ATOMS
20
= 10 per cubic mm FLOW IN A
(100 BILLION BILLION) CONDUCTOR
 A POTENTIAL DIFFERENCE or CHARGE ,across a conductor, causes ELECTRONS to

flow towards the positive charge, (electrons are negatively charged).
The level of CHARGE is measured as VOLTAGE .
 CURRENT flow is possible because of ‘free’ electrons in the atoms from which the
conductor is made.
 CURRENT flow can also be described in terms of electron flow.

 1 Ampere flowing in a conductor at a given point in time would be equal to :-
 6 X 1018 electrons flowing / per second.

WHAT ARE CONDUCTORS
CONDUCTORS IN CONDUCTORS
A DOMESTIC IN A
CABLE GENERATOR
WINDING
IRON
CORE
 Conductors are materials where the atoms have free electrons which can flow from
atom to atom, when induced by an electric charge (voltage).
 Most metals are good conductors, some of the best being silver, copper and gold.
Good conductors have a very low resistance to current flow.
 Copper conductors are generally chosen for Generator windings because of its
good electrical and thermal conductivity, relatively low cost, ease of use.

WHAT ARE INSULATORS
INSULATION IN INSULATION
A DOMESTIC IN A
CABLE GENERATOR
WINDING
IRON
CORE
 Insulators are materials where, the electrons are very tightly bound to the nucleus
and to other atoms, (covalent bonding), hence there are no free electrons to carry an
electrical charge.
 As a result, they are are a very poor conductors of electricity.
 Typically rubber,plastics, ceramics and glass are good insulators. They have a very
HIGH resistance to current (electron) flow.
 The Voltage level, temperature rise, electrical, and mechanical properties, all
determine the type of insulation materials chosen for a Generator winding.

WHAT IS D.C (DIRECT CURRENT)
+ -
12V D.C
BATTERY
 Direct Current (DC) Voltage, can be produced by converting chemical

energy directly into electrical energy. This is the BATTERY.
 A BATTERY is a storage device, i.e., the battery stores potential energy,

which is known as the ‘charge’.
 The first battery was invented by VOLTA in 1800, and was called the
VOLTAIC PILE.

COUNT ALESSANDRO GIUSEPPE ANTONIA VOLTA 1745 - 1827
VOLTAIC PILE
COPPER
& ZINC
CELLS
IN HE FOUND
SALT IT QUITE
WATER SHOCKING!
SOLUTION
 In 1800,Volta invented the “VOLTAIC PILE”, which was the first BATTERY, and the
first Electrical device to produce a continuous ELECTRICAL CHARGE.
 The VOLTAIC PILE was the fore- runner of the modern battery, with all its many
varieties today.

A SIMPLE D.C CIRCUIT
Electron flow
Copper
Conductor
Light
Switch Bulb
+ + -
D.C
BATTERY
 The battery creates a POTENTIAL DIFFERENCE or CHARGE across its terminals.

 We measure this charge as VOLTAGE.
 The battery acts like a ‘pump’, forcing electrons to flow around the circuit.
 When the switch is closed, the potential difference causes free electrons to flow
through the conductors, and the light filament.
 The thin tungsten filament in the bulb acts as a ‘restriction’, or ‘resistance’, to the
electron flow, heating the element and producing light.

WHY IS D.C USED IN AN A.C GENERATOR?
A.C GENERATOR SET
ALTERNATING
D.C CONVERTED
CURRENT
FROM A.C
A.C
+V
0v
V
Anode
Gate
 Silicon Controlled
 Rectifier Diode
Rectifyer (Thyristor)
Cathode
 All Generators produce Alternating Current (A.C).

 A D.C Generator is an A.C Generator, with its output converted into D.C by means
of commutation, (reversal of the Negative cycle).
 In A.C Generators, D.C is produced by means of RECTIFICATION.
 D.C is used to produce the ELECTRO MAGNETIC FIELDS in A.C Generators.

WHAT IS A.C ( ALTERNATING CURRENT ) ?
 A.C Electricity (Alternating Current ), is produced by converting mechanical

energy into electrical energy. This is the A.C Generator.
 The mechanical energy is provided by an Engine, or Turbine which drives the

Generator.
 The Engine or Turbine may be powered by various forms of potential energy i.e. :-
 Fossil fuels, (Petrol, Diesel, or Gas), or fuels from waste products (Methane).
 Steam from the heat produced by burning fossil fuels, or nuclear energy .
 Water Turbines, (Hydro Electricity), driven by the pressure of water from a river
or Dam.
 Alternative energy produced by wind or wave turbines.

THE A.C GENERATOR
PRIME MOVER
(ENGINE OR TURBINE) A.C GENERATOR
 Mechanical power (HORSEPOWER) is converted into electrical power (KILOWATTS,

or kW) by means of a prime mover (engine) driving the A.C Generator.

WHAT IS A.C POWER ?
AP
PA
R EN
T PO
REACTIV WE
R(
E (kVAr) kV
N S A)
LAGGING
C OS 
INDUCTIVE CAPACITIVE 90º
CIRCUIT CIRCUIT ACTIVE POWER ( kW )
 ELECTRICAL POWER, (WATTS) in its simplest form = VOLTAGE X CURRENT

 A.C creates WASTED CURRENT in INDUCTIVE or CAPACITIVE circuits.
 The resultant APPARENT POWER , is called the kVA
 The POWER FACTOR, (COSINE of the phase angle ), is a measure of the WASTED
or WATTLESS CURRENT component of the load.
 Generator output RATINGS usually give the full load kWATTS and kVA at 0.8 P.F.
SO, HOW DOES AN A.C GENERATOR PRODUCE A.C POWER ?

CAN ANYONE GUESS WHAT THIS IS ?
CAN ANYONE GUESS WHAT THESE ARE ?
ZANUSSI
CORRECT !!
FRIDGE MAGNETS.
BUT WHAT’S THAT GOT TO

DO WITH A.C GENERATORS ?

MAGNETISM IN GENERATORS
MAGNET
MAGNETIC
N S FLUX
 Magnetism is the essential force which produces the ELECTRO MOTIVE FORCE
(EMF), in a Generator.
 Without MAGNETISM, you would have no fridge to stick your fridge magnets to !!

ELECTRO- MAGNETISM IN GENERATORS
CONVENTIONAL
- + CURRENT FLOW
(AMPERES)
D.C COPPER COIL
BATTERY (MAGNETIC FIELD)
MAGNETIC
N S
FLUX
 When a D.C supply is connected to a copper coil, current will flow in one
direction through the coil, creating a magnetic field.
 If an iron core is placed into the magnetic field, it will become magnetized. The
magnetic strength is determined by the D.C power (Voltage X Current) in the coil.
 This is the principle of ELECTRO-MAGNETISM, which is used to control the
magnetic fields in an A.C Generators.

MICHEAL FARADAY 1791 - 1864
 In 1831, Michael Faraday, using a simple magnet and a coil of wire,discovered that
mechanical energy could be converted into electrical energy,

SIMPLE FARADAY GENERATOR
ELECTRIC WATCH THE

LIGHT BULB
LIGHT BULB !
MAGNET
COPPER COIL
(CONDUCTOR)
N S
 When the magnet is stationary, no work is being done, so no electricity is generated.
 When the magnet is moved rapidly passed the coil, work (energy) is being done, and
this will generate the ELECTRO MOTIVE FORCE, (EMF or VOLTAGE), into the coil.

BASIC PRINCIPLES OF AN A.C GENERATOR
Permanent Magnet Field

Magnetic Field
(Flux)
N
Shaft
Copper Slip-rings
loop and Brushes
S THIS TIME THE
MAGNETS ARE
STATIONARY, BUT THE
COIL IS MOVING !
+VE Output
-VE
A.C Sinusoidal Output Voltage with A Permanent Magnet Field

BASIC PRINCIPLES OF AN A.C GENERATOR
Electro- Magnetic
Magnetic Field Field
(Flux)
ADJUSTABLE
D.C SUPPLY
Shaft
Copper Slip-rings
loop and Brushes
+VE Output
-VE
By controlling the D.C current into the magnetic field, the voltage level can be
adjusted, allowing control of the output voltage.

SIMPLE A.C GENERATOR
AIR GAP ELECTRO
(MAGNETIC MAGNETIC
LINES OF FIELD
FORCE OR
D.C FIELD POLES
FLUX)
A.C OUTPUT
CARBON
BRUSHES
SHAFT
SLIPRINGS
A.C
ARMATURE
WINDINGS ADJUSTABLE
D.C SUPPLY
 The output Voltage is a product of (A), the strength of the magnetic field, (B),
the length of conductors in the A.C armature (turns), and (C), the velocity
(speed) of the conductors cutting the magnetic lines of force.

WHY DO WE CHOOSE A.C, AND NOT D.C ?
Magnetic Lines THE TRANSFORMER
of Force
(Alternating Laminated
flux) Steel Core
Primary Secondary
Winding Winding
(Input) (Output)
A.C can be increased or decreased by means of MUTUAL INDUCTION.

 This is achieved by the TRANSFORMER, and is essential for POWER DISTRIBUTION.
 SECONDARY VOLTAGE = RATIO OF PRIMARY TURNS : SECONDARY TURNS

 The A.C transformer enables us to distribute A.C POWER over very large distances.
 D.C cannot be transformed, and can only be distributed at the generated voltage.
WHY IS THIS IMPORTANT ?

DISTRIBUTION OF A.C POWER
MAINS SUPPLY STEP UP

A.C GENERATOR TRANSFORMER
CB SUPER HIGH
TENSION
400,000V
MCB
STEP DOWN
TRANSFORMER
MCB
 A.C Voltage can be increased or decreased by transformers,

 By increasing the Voltage, overhead supply cables can be made much lighter.
This allows load currents to be distributed over long distances at very high voltages.

TYPICAL ROTATING ARMATURE A.C GENERATOR
MAGNETIC CARBON
FLUX BRUSHES
D.C FIELD POLES OUTPUT A.C
SHAFT A.C.ARMATURE
SLIPRINGS
BEARINGS
D.C INPUT
 Before the Late 1960’s, Newage A.C Generators were designed with a rotating A.C
armature, from which the Generator output was taken.
 This was achieved by means SLIP-RINGS and carbon ‘ BRUSHES’
 These had a tendency to wear out, spark, burn, and required regular maintenance.
 Newage switched to Brushless Generator design in the Late 1960’s.
This became feasible following the invention of the Silicon Diode Rectifier

TYPICAL ROTATING D.C FIELD GENERATOR
OUTPUT A.C CARBON
BRUSHES
MAGNETIC A.C STATOR D.C SUPPLY
FLUX
SHAFT D.C.FIELD (ROTOR)
SLIPRINGS
BEARINGS
 This generator has a rotating field (rotor), which is supplied with D.C via two slip-rings.
 The output is taken from the static A.C windings ( Stator),
 This design is still popular today, as the rotating field system is easier to design than
a rotating armature, and more economical to manufacture.
 The main components of a Brushless Generator are of a similar design to above.
 However, Brushless Generators are designed without slip-rings and brushes.
 NOW LETS LOOK AT A BRUSHLESS GENERATOR

TYPICAL BRUSHLESS A.C GENERATOR
RECTIFIER EXCITER ROTOR
OUTPUT A.C DIODES EXCITER STATOR
MAGNETIC A.C STATOR

FLUX
SHAFT D.C.FIELD (ROTOR)
BEARINGS
 The SLIPRINGS and BRUSHES are now replaced with :-

 The RECTIFYER ASSEMBLY which converts A.C VOLTAGE into D.C VOLTAGE.
 The EXCITER ROTOR, which provides A.C POWER to the RECTIFIER.
 The EXCITER STATOR, which is the ELECTRO-MAGNETIC FIELD for the
EXCITER ROTOR.
 NOW LETS SEE HOW A BRUSHLESS GENERATOR WORKS

BRUSHLESS GENERATOR COMPONENT ASSEMBLY (TWO BEARING)
Main Rotor Main Stator

Exciter Rotor
Exciter Stator Fan
Bearing Bearing
Cartridge Cartridge
N.D.E D.E
Key
Shaft
P.M.G
Rotor
Rectifier
P.M.G
Stator

BRUSHLESS GENERATOR COMPONENT ASSEMBLY (SINGLE BEARING)
Main Rotor Main Stator

Single bearing
Exciter Rotor
Coupling
Exciter Stator Fan
Bearing
Cartridge
N.D.E
P.M.G
Rotor
Rectifier
P.M.G
Stator

Main
HC Generator Assembly
Terminals
Main Rotor
A.V.R.
on A.V.M,s Main Stator
Drive end
Fabricated
Bracket
Non drive Frame
end Bracket
& Exciter
Stator assy
P.M.G
Rotor
P.M.G
Stator

Air flow through Generator
 Air flow must not be restricted

Excitation System
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan

Excitation System - Exciter Stator
Exciter
Stator
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan

Excitation System - Wound Exciter Stator
X+ (F1)
XX- (F2) To A.V.R Terminals
COIL CONNECTIONS
N S N S
 High-remanence steel core

 Stores Residual Magnetism
 12-14 pole magnet field
 High frequency Generator

Excitation System - Exciter Rotor
Exciter
Rotor
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan

Excitation system - Exciter Rotor Assembly
W
U
SHAFT V
W
 3 Phase A.C output, each Phase connected to 2 diodes on Main Rectifier.
 High Frequency output, ( from12 to 14 Pole Exciter Stator ).
 Exciter generator is a magnetic power amplifier for the main rotor current.

Excitation System - Exciter Rotor/ Main Rectifier
Exciter Rotor and

Main Rectifier
Circuit
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan

Exciter Rotor and Rectifier Assembly
 Wound Exciter Rotor

W
U
 Rectifier Assembly
SHAFT
SHAFT V
W
 Rectifier Assembly Mounted on Exciter rotor Core, (drive end side).
 NOTE: BC & Frame 8 Generators are mounted at the non-drive end side.

Exciter Rotor & Main Rectifier Assembly
Exciter Rotor 3 Phase

with Internal Star Point
SHAFT

Exciter Rotor & Main Rectifier Connections
 Rectifier Input Terminal
SHAFT
SHAFT
 3 Phase A.C Exciter Rotor Connected to Rectifier input terminals

Excitation System - The Main Rectifier
Main
Rectifier
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan

The Main Rectifier Assembly
 3 Phase A.C Input  Aluminium
from Exciter Rotor. Heat-sinks
(Insulated Terminals)
 Varistors
(Surge Suppressors)
 Rectifier Hub
 Rectifier Diodes
Negative Plate
Anode Stud SHAFT
 Rectifier Diodes
Positive Plate
Cathode Stud
 Output to
Main Rotor

Main Rectifier Assembly- Operation of a Diode
+VE
 A.C Input to Rectifier 0

Diodes
 Rectifier Diode -VE
Positive Heatsink
Cathode Stud
+VE
+ 0
-VE
 Rectifier Diode
Negative Heatsink +VE
Anode Stud
0
-VE
 for a 12 pole exciter field the frequency will be 150 or 180 HZ

(cycles/second).

Main Rectifier Assembly- 3 Phase Rectification
 A.C Input to Rectifier

Diodes
 D.C output to Main Rotor

+
-
 Full wave 3 Phase rectification will produce a D.C output of 1.35 X A.C input
voltage

Metal Oxide Varistor (Surge Suppressor)
 UC & BC Type 350 Volt  HC & F8 Type 778 Volt

 Clamping @ 30 Amp 680 Volts  Clamping @ 100 Amp 1365 Volts
Diode Protection Device

For Transient Suppression
SHAFT SHAFT
Main Rotor
Connections

Metal Oxide Varistor (Surge Suppressor)
DIODE PROTECTION DEVICE
Typical high voltage transient created by

Direction of transient
fault condition in the distribution system.
Up to 2- 3000V (peak voltage)
High Transient surges can be created by:-

 Energy absorbed  ‘ Crash’ Synchronising onto live bus-bars.
by Varistor.
 Electric storm, (lightning), and field effects on
overhead lines (distribution systems).
 Varistor clamping  Arcing, caused by faulty switching, motor
(Protection) level. failure, short circuits in the distribution system.
Full load D.C D.C supply

output from t = µ sec's. to Main
main Rectifier rotor

Excitation System - The Main Rotor
Main Rotor
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan

Main Rectifier Connections to Main Rotor
Main Rectifier Main Rotor

 Aluminium
Heat-sinks
SHAFT D.C
 The Rectifier Output is a smooth D.C Supply across the Aluminium Heat Sinks
 This is fed to the Main Rotor windings

Wound Main Rotor - Coil Group connections
ANTI CLOCK
D.C Input
From Main S
Rectifier
CLOCK CLOCK
N N
ANTI CLOCK
 The Rotor coils are connected in Series (4 Pole Rotor shown).

 Each coil is reversed to the adjacent coil, producing the required polarity

Wound Main Rotor - Poles & Frequency
Generator Frequency (HZ) = Speed (N) X Pairs of poles (P)

60
6 Pole Available
4 Pole in Frame 7
2 Pole
S
N
SHAFT
N
N
SHAFT
S
S

 Main Stator Core

 Main Stator Coils in Slots (section) (section)
 4 Pole Main Rotor
 Air Gap
 1 Cycle S
N
SHAFT
 Consider the Coils in the slot at 12 O'clock position, marked with the ARROW.
 The NEGATIVE Pole of the 4 pole Rotor is directly under the slot, therefore the
coil conductors in this slot will be going fully NEGATIVE

 Main Stator Coils in Slots  Main Stator Core

 Air Gap
1 Cycle
N
S
S
H
A
FT
N
S
 The Rotor has now rotated Clockwise 45 º, until exactly half-way between
Negative and Positive Poles appears beneath the 12 O'clock position.
 The coil conductors in this slot will now be at ZERO VOLTAGE.

 Main Stator Coils in Slots  Main Stator Core

 Air Gap
1 Cycle N
S
SHAFT
 The Rotor has now rotated Clockwise 90 º, until the POSITIVE Pole is DIRECTLY
UNDERNEATH the 12 O'clock position.
 The coil conductors in this slot will now be at the FULLY POSITIVE position
 The 4 Poles will produce 2 FULL CYCLES for each 360 º FULL REVOLUTION.

Generator Frequency (HZ or CYCLES) = Speed (N) X Pairs of poles (P)

60
FRQUENCY NUMBER ENGINE

HZ (CYCLES) POLES (P) SPEED (N)
50 2 3000
2 Pole 1 HZ = 60 RPM
50 4 1500 4 Pole 1 HZ = 30 RPM
6 Pole 1 HZ = 20 RPM
50 6 1000
60 2 3600
60 4 1800
60 6 1200

Main Rotor- Amortisseur (Damper) Windings
S  Amortisseur Winding (Damper Bars)

(Aluminium Damper Bars Welded to End Plates )
N
N
SHAFT

Main Rotor- Amortisseur (Damper) Windings
 Helps dampen speed oscillations resulting from cyclic

irregularities in the engine, (cause of ‘light flicker’).
 Stabilises the mechanical systems during large load
changes.
 Stabilises load sharing with other Generators in Parallel.
 Improves Harmonic Distortion in the Generator waveform

Operation - Main Stator
Main Stator
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan

Wound Main Stator Assembly
 The Main stator insulation is class H as standard, allowing up to 165º C temperature.

 The laminated core is built from high grade Electrical Steel to minimise Iron losses.
 12 Ends Out Re-connectable, or 6 Ends out Star / Delta, or Dedicated Windings.
 Windings are standard for most voltages, special windings required for some
voltages
Output Leads Laminated Steel core Copper Windings

 Core length of Stator & Rotor (L) Determines KVA Rating for each Frame size,e.g.
 HC4 C, D ,E, F Core Lengths = 250 KVA to 400 KVA (@ 50 HZ)
 HC5 C, D, E, F Core Lengths = 450 KVA to 675 KVA (@ 50 HZ)
 HC6 G, H, J, K Core Lengths = 800 KVA to 1110 KVA (@ 50 HZ)
 HC7 E, F, G, H Core Lengths = 1350 KVA to 2000 KVA (@ 50 HZ)
Core lengths
Output Leads Copper Windings

Laminated Steel core

Stator Winding Coils (Lap winding)
COIL PHASE GROUP
OUTPUT CONDUCTORS
OUTPUT
CONDUCTORS
COIL END
(OVERHANG)
COIL
STATOR SPAN COIL
CORE (PITCH) TURNS
LENGTH
 The output voltage of the stator is determined by the number of turns per coil, the
stator core length, the velocity of the magnetic field (rotor), and the strength of the
magnetic field.
The Current capacity of the coil is determined by the conductor cross sectional
area, and number of conductors in parallel.

Typical Main Stator 12 Wire Re-connectable
GROUP 1
2/3RDS PITCH
WINDING LEADS V6 V2
8 SLOTS
START OF COIL U5 W1
( SPAN 1 TO 9)
GROUP U1
W5 ONE PHASE GROUP
WINDING LEADS W2
( 4 COILS PER GROUP)
FINISH OF COIL U6
GROUP
W6 FULL PITCH
12 SLOTS
S U2
( SPAN 1 - 13)
V5
GROUP 3 UP 4
V1 GRO
N
SHAFT
V1
V5
U2 S
W6
U6 W2
W5
U1
W1 U5 MAIN STATOR WINDING
V2 V6
MAIN ROTOR SECTION ( 48 SLOT )
GRO UP 2
(4 POLE)

Typical Main Stator 12 Wire Re-connectable
 Connections shown in Series Star
6
WV6
N U6 Neutral
6 W5
W1
W2 W
AVR Sensing 3 Phase Output
& Power supply 7 V5
from Main Stator V2
V V1
U5
8
U2
U U1

Wound Main Stator 12 Wire Re-connectable
Series Star Parallel Star

Voltage Range (winding 311) Voltage Range (winding 311)
380 to 440 V @ 50 HZ U U 190 to 220 V @ 50 HZ
416 to 480 V @ 60 HZ 208 to 240 V @ 60 HZ
U1 8
U1 U5
U2 U5
8
U2 U6
W6 U6 N
W2 N V6
6 V6
V2
W2 V5
W1
W5 V5
W1 7 V1 6 W6 V2
w v w W5 V1 v
7
 The stator windings are connected into six groups.
 The groups can be connected by Newage, or the customer, to provide different voltage
requirements.
 Special Voltage requirements require special windings, e.g.; 690 Volt for Co-Generation.

Wound Main Stator 12 Wire Re-connectable
Series Delta Double Delta

U
8 6
Centre W6 U1
Tap V1
W5 U2 V5 W2 W6
W2 U5 V2
V6 W1 W5
6 W1 U6 7 8 7
V6 V5 V2 V1 U1 U2 U5 U6
w v U N w
Voltage Range (winding 311) Voltage Range (Winding 311)

220 to 250 V @ 50 HZ, 240 to 277 V @ 60 HZ 220 to 250 V @ 50 HZ, 240 to 277 V @ 60 HZ
No Neutral connection. Single Phase Only, output across U & W
Centre Tap for low volts 1ph only Centre Tap (N) for low volts
110 to 125 @ 50 HZ, 120 to 138 @ 60 HZ

Wound Main Stator 6 Ends Out
Star
U
8
Voltage Range (winding 312) Number of Stator leads in parallel
380 to 440 V @ 50 HZ, 416 to 480 V @ 60 HZ U1 multiply’s with current rating
Single Phase (N) = 3 of Phase voltage of generator,
Dropper transformer required ie: 12, 18, 24, 36, or 48 leads out.
for AVR sensing U2
N
W2 V2
7
6 W1 V1
w v
Each phase group is producing the full line voltage, (all coil groups in each phase are in
parallel).

AVR INPUT TERMINALS - SENSING SUPPLY
Sensing Supply to A.V.R for 6 ends out STAR connected
U
8
Examples - 6 ends Stators
Winding 312 U1
380 to 440 V @ 50 HZ
416 to 480 V @ 60 HZ
Single Phase (N) = 3 of L-L
U2 Isolation transformer
Winding 26 8
660 - 690 Volts @ 50 HZ N
W2 V2
7
W1 V1 7
w v
6 6
 The AVR Sensing supply is connected to the main stator via a sensing
isolation transformer, which is fitted in the main terminal box.
 Other windings producing higher voltage requirements will require a different
transformer ratio, to supply the AVR with the correct voltage adjustment range

Excitation Control - Automatic Voltage Regulator (A.V.R)
The A.V.R
A.V.R
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan

Excitation System - Self Excited Generators
X+ (F1)
D.C Output A.C Power &
XX- (F2) A.V.R
From A.V.R Feedback Signal
Into (Sensing)
Exciter Stator From Main Stator
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan

Automatic Voltage Regulator (AVR) Type SX460/2 (Self -Excited)
VOLTS X XX 6 7 8
1
2
3
4 WARNING!
ELECTRIC SHOCK
[Live Terminals]
UFRO
50HZ
C
60HZ
STABILITY

Automatic Voltage Regulator (AVR) Type SX440 (Self Excited)
K2 K1 P2 P3 P4 XX X 3 2 2 1
S2 S1 A2 A1
TRIM
Input Var/ PFC3
[Live Terminals]
ELECTRIC SHOCK
WARNING!
DROOP Input Droop C/T
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
VOLTS
Linking for
3 Phase
Sensing Unit
UFRO STABILITY C B A
50 C 60

Automatic Voltage Regulator (AVR) Type MX341 P/N E000-23412/1P
K2 K1 P2 P3 P4 XX X 3 2 2 1
S2 S1 A2 A1
TRIM
MX341-2 E000-23412
[Live Terminals]
ELECTRIC SHOCK
WARNING!
DROOP
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
VOLTS Linking for
3 Phase
Sensing Unit
EXC
DIP TRIP
UFRO STABILITY
3 2 C B A
1

Automatic Voltage Regulator (AVR)
P4
Type MX321 P/N E000 -23212
K2 K1 P2 P3 P4 XX X 6 7 8 1 2
VOLTS
RAMP
FREQUECY I /LIMIT
SELECTION
UFRO
3 2 1
ELECTRIC SHOCK
[Live Te rminals]
WARNING!
DIP
R.M.S
DWELL
STABILITY
STABILITY
SELECTION
OVER/VOLT U V W DROOP TRIM

EXC TRIP S1 S2 S1 S2 S1 S2 A1 A2
E0 E1 B0 B1 C B A

Operation of AVR - as an electronic switch
 DIODE CIRCUIT  SILICON CONTROLLED RECTIFIER (SCR)
Gate
A.C Power A.C Power

Supply AVR Supply
Control
Circuit
X
1/2 Wave D.C 1/2 Wave D.C

Exciter field Exciter field
 A DIODE will conduct continuously, producing half wave rectification of the A.C supply.
 A DIODE, however, would not CONTROL the D.C into the exciter field, which is necessary
to control the Generator voltage.
 A SILICON CONTROLLED RECTIFIER (SCR or THYRISTOR) is a diode with a control
GATE.
 The SCR will only switch ON when the GATE receives a signal from the AVR controls.

D.C Pulses
From A.V.R Into A.V.R  A.C power supply from
Exciter Stator Main Stator
X+ (F1) XX- (F2)  Sensing Supply

Exciter (2 or 3 phase)
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
The AVR switches the D.C power supply ON and OFF 50 - 60 times per second.
 For PMG powered AVR,s 100 - 120 times per second.

Phase Control of AVR power supply (Self Excited)
AC power supply to
AVR 170 to 240V.
50 or 60 HZ .
D.C Power supply (1/2 cycle rectification)
Power ON
After time (T)
 Number of pulses are the same as the A.C power
OFF OFF
supply frequency (50 or 60/second)
 NO LOAD D.C Pulses into the Exciter Stator X+(F1) XX-(F2)
(T)  The power device (Thyristor or SCR) is switched ON by the control

circuit, after time delay (T).
 The Thyristor automatically switches OFF as the power supply pulse

falls to zero after each cycle.

Power ON
After time
(T)
OF OF
F F
 FULL LOAD D.C Pulses into the Exciter Stator X+(F1) XX-(F2)
(T)
 As LOAD is increased , the time delay (T), will automatically decrease.
 The larger the pulse area (in RED) the higher the D.C power into the exciter stator..
. The AVR will stabilise at the new output level , when the sensing signal into the
AVR has returned to normal (nominal) voltage, as pre-set on the ‘VOLTS’ adjustment.


Power ON
After time (T)
OFF OFF
 OVERLOAD D.C Pulses into the Exciter Stator X+(F1) XX-(F2)

(T)
Although the red pulses are now termed ‘OVERLOAD’, the AVR requires this
additional power to provide a rapid response to transient load application, ( to
reduce voltage DIP).
 This short term response demands ALL of the power supply available for
approximately 0.3 seconds, until the output voltage has returned to normal.

Excitation System - Separately Excited Generators
The Permanent Magnet Generator

(PMG)
P2, P3, P4 Power Supply To A.V.R
 Generator Shaft (Non-Drive -End)
 Dowel Pin for PMG Rotor Location

 Ceramic Magnet Rotor, highly magnetic saturated field. 8 Pole Rotor , 100 HZ
(at 1500 RPM ) or 120 HZ (at 1800 RPM )
 Through Bolt fixture to Shaft non drive end
 Permanent Magnet Stator 3 Phase A.C 170 to 220 Volts, separate power
supply for the A.V.R

P.M.G Assembly UC Frame sizes

PMG Rotor & Stator Assembly - HC Frames
 Optional on HC4,& HC5

 3 Phase A.C, 170- 220 Volts
P.M.G
Rotor
P.M.G
Stator
in Housing

PMG
Power
P2 -P3 -P4 X+ (F1) A.V.R A.C Feedback
Supply 6-7-8 Signal only.
To A.V.R
XX- (F2) (Sensing)
Main Stator from Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan

 Advantages of the PMG System
 The PMG is a separate power supply for AVR, which is

unaffected by adverse loading conditions such as :-
Waveform distortion caused by non linear loads

Transient fault conditions in the distribution system.
 Provides a powerful voltage build up system on initial run-

up, (does not rely upon residual magnetism)
 Provides sustained short circuit current under fault

conditions, (requirement for all Marine classifications).


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NEWAGE PRODUCT TRAINING

NEWAGE PRODUCT TRAINING

 Electricity is a NATURAL form of ENERGY, e.g, LIGHTENING,

 ALL forms of MATTER in the Universe, (solid, liquid or gas), are

 An electrical CHARGE, (or POTENTIAL DIFFERENCE),measured

 This CHARGE, (or VOLTAGE), provides the ‘pressure’ in an

Lets take a closer look at the ATOM

NEWAGE PRODUCT TRAINING

NEWAGE PRODUCT TRAINING

 A POTENTIAL DIFFERENCE or CHARGE ,across a conductor, causes ELECTRONS to

 CURRENT flow can also be described in terms of electron flow.

NEWAGE PRODUCT TRAINING

NEWAGE PRODUCT TRAINING

NEWAGE PRODUCT TRAINING

 Direct Current (DC) Voltage, can be produced by converting chemical

 A BATTERY is a storage device, i.e., the battery stores potential energy,

NEWAGE PRODUCT TRAINING

NEWAGE PRODUCT TRAINING

 The battery creates a POTENTIAL DIFFERENCE or CHARGE across its terminals.

NEWAGE PRODUCT TRAINING

 All Generators produce Alternating Current (A.C).

 D.C is used to produce the ELECTRO MAGNETIC FIELDS in A.C Generators.

NEWAGE PRODUCT TRAINING

 A.C Electricity (Alternating Current ), is produced by converting mechanical

 The mechanical energy is provided by an Engine, or Turbine which drives the

NEWAGE PRODUCT TRAINING

 Mechanical power (HORSEPOWER) is converted into electrical power (KILOWATTS,

NEWAGE PRODUCT TRAINING

 ELECTRICAL POWER, (WATTS) in its simplest form = VOLTAGE X CURRENT

SO, HOW DOES AN A.C GENERATOR PRODUCE A.C POWER ?

NEWAGE PRODUCT TRAINING

BUT WHAT’S THAT GOT TO

NEWAGE PRODUCT TRAINING

NEWAGE PRODUCT TRAINING

NEWAGE PRODUCT TRAINING

NEWAGE PRODUCT TRAINING

ELECTRIC WATCH THE

NEWAGE PRODUCT TRAINING

Permanent Magnet Field

NEWAGE PRODUCT TRAINING

NEWAGE PRODUCT TRAINING

NEWAGE PRODUCT TRAINING

A.C can be increased or decreased by means of MUTUAL INDUCTION.

 SECONDARY VOLTAGE = RATIO OF PRIMARY TURNS : SECONDARY TURNS

NEWAGE PRODUCT TRAINING

MAINS SUPPLY STEP UP

 A.C Voltage can be increased or decreased by transformers,

NEWAGE PRODUCT TRAINING

NEWAGE PRODUCT TRAINING

SHAFT D.C.FIELD (ROTOR)

NEWAGE PRODUCT TRAINING

MAGNETIC A.C STATOR

SHAFT D.C.FIELD (ROTOR)

 The SLIPRINGS and BRUSHES are now replaced with :-

NEWAGE PRODUCT TRAINING

Main Rotor Main Stator

NEWAGE PRODUCT TRAINING

Main Rotor Main Stator

NEWAGE PRODUCT TRAINING

NEWAGE PRODUCT TRAINING

 Air flow must not be restricted

NEWAGE PRODUCT TRAINING

NEWAGE PRODUCT TRAINING