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A LT E R N AT O R S RANGE

A A G

A A K

A A K c o m p a c t

A A N c o m p a c t

A A T
A LT E R N AT O R S ISKRA

The technical performance of Iskra alternators is based on long-term relationships with the customers, their high

requirements and expectations and our own long-standing experience in development and production. We control

quality using ISO 9001 and QS-9000 standards. The entire process from customer requirement and expectation,

through development and production is planned and controlled in detail. High operating reliability is assured by

optimising the design for use in different operating conditions, together with numerous validations of different

alternators in Iskra's own laboratories and on vehicles.

Alternators are air-cooled synchronous three-phase generators with claw poles and a built-in semiconductor rectifier.

A three-phase stator winding is connected to the three-phase rectifier bridge with power rectifier or Zener diodes.

The rotor coil is connected to the slip rings with brushes that conduct the excitation current. Alternators are self-

excited through excitation diodes or they are excited directly by the battery. The voltage regulator can be either

built-in or separately mounted. The negative terminal is normally connected to the chassis.

Iskra Avtoelektrika keeps abreast of all technical innovations in the field of alternators. Its staff are aware that energy

conservation in vehicles is an absolute necessity. The results are different families of alternators designed in modern

compact versions with internal fans in parallel with families of conventional design using external fans. Modern

versions of rectifiers and specific multifunction regulators are also available.

Different versions of alternators meet very high specifications in terms of resistance to salt spray, humidity, water,

mud, dust, vibrations, high and low temperatures and aggressive liquids. They are also designed to meet electromagnetic

compatibility and other international directives and standards. They are produced using ecologically sound technologies

and environmentally friendly materials.

Iskra alternators are designed to meet a wide range of engineering specifications and applications. They are used

on petrol and diesel engines in the automotive industry, on trucks, buses, tractors, construction machinery and in

other applications. Different solutions of our alternators are defined taking into account the demands of each

application and are designed for long life, maintenance free operation under extreme conditions.

CLASSIFICATION OF ALTERNATORS

Alternators type AAG stator diameter 108 mm


Alternators type AAK stator diameter 125 mm
Alternators type AAK compact stator diameter 125 mm
Alternators type AAN compact stator diameter 142 mm
Alternators type AAT stator diameter 165 mm
A LT E R N AT O R S 14 V , 2 8 V

ALTERNATORS 14V

100

90

80
AAN compact
70

60
7.3kg
50

AAK compact
Output in Amps. at 1800 RPM

40

30 AAK 5.3kg

20 4.7kg
AAG

10 3.5kg

0
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160

Output in Amps. at 6000 RPM

ALTERNATORS 28V

100

90
AAT

80

70

60

50 14kg

AAN compact
Output in Amps. at 1800 RPM

40

30 7.3kg

AAK compact
20
5.3kg
AAK
10
AAG 4.7kg
3.5kg
0
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160

Output in Amps. at 6000 RPM


A LT E R N AT O R S AAG

APPLICATIONS
Low output powers make it possible for the
alternators to be built into systems with low
electrical requirements. Small dimensions allow
installation on all types of combustion engines
used on small tractors, small agricultural
machinery, stationary engines and some other
applications.

DESIGN
The alternator is a three-phase, 12-pole
synchronous self-excited generator with built-
in rectifier and regulator and cooled by an
external fan. Various design solutions are
available depending upon the application:
insulated, marine, dustproof and other versions.

Cooling
The integral fan provides effective through cooling
of the alternator. Two different fans are available,
for CW and CCW direction of rotation.
MAIN TECHNICAL DATA
Rotor
Type AAG The rotor winding fixed between the claw poles
provides excitation of the alternator through slip
Nominal voltage 14V 28V rings. For particularly dusty environments slip rings
and brushes are additionally protected.
Nominal current 33A - 50A 18A
Rectifier
Stator diameter 108 mm Press fit rectifier diodes or Zener diodes are mounted
into protected heat sinks. Zener diodes protect the
Weight ~3.5 kg without pulley loads on the vehicle against overvoltages from the
alternator.
Max. speed 18,000 RPM
Regulator
Regulator Built-in or separate The regulator incorporating the brush holder is built
Hybrid technology into the alternator. The regulator is produced using
thin-film hybrid or microelectronic technology.
Pulleys and drive Different types according to Monofunction or multifunction is available
end brackets customers' requirements depending upon the requirements of the application.
The highest quality brushes ensure long life of the
Terminals Screw and/or blade terminal alternator.

Drive end bearings Type 6203 – 2RS Brackets - Bearings - Pulleys


Brackets, bearings and pulleys are made according
Rear end bearing Type 63001 to the customers’ requirements. A range of special
sealed bearings makes it possible to design
Power diodes Press fit rectifier diodes or Zener diodes alternators for specific installations, operating in
the harshest conditions whilst achieving long,
Protection of the slip Protected against access by a wire maintenance free life.
rings and brushes or splashing water (IP 44)
Protected against ingress of solid foreign Electrical terminals
matter and powerful water jets (IP 56) Electrical terminals are according to the customers’
requirements.
Ambient temperature From - 40ºC to + 110ºC
A LT E R N AT O R S AAG

CROSS SECTION 3 4 5 6 7 8 9 10

2 11
Pos 1 … Pulley
Pos 2 … Drive end bearing 1 12
Pos 3 … Fan
Pos 4 … Drive end bracket 13
Pos 5 … Stator
Pos 6 … Rotor 14

o 108 mm
Pos 7 … Rear bracket
Pos 8 … Snap ring 15
Pos 9 … Sealing felt
Pos 10 …Rectifier 16
Pos 11 …Slip rings
Pos 12 …Terminals B+, W, D+
17
Pos 13 …Capacitor
Pos 14 …Rear bearing
Pos 15 …Brush
Pos 16 …Brush holder with voltage regulator
Pos 17 …Rubber gaskets 123 mm

CHARACTERISTICS

I(A) I(A)
60 20
18A
50A
45 15

35A
33A
30 10

15 5
U=const.=13V U=const.=27V
To=23ºC±5ºC To=23ºC±5ºC

0 0
0 1000 2000 3000 4000 5000 6000 7000 0 1000 2000 3000 4000 5000 6000 7000

n(RPM) n(RPM)

I (A) at I (A) at I (A) at I (A) at


n ° (RPM) 1800 RPM 6000 RPM n ° (RPM) 1800 RPM 6000 RPM
14V 33A 1150 15 32 28V 18A 1200 8 18
14V 35A 1250 13 35
14V 50A 1250 20 48

CONNECTION DIAGRAM D+ B+ B- W D-
REGULATOR

DF D+
G
A LT E R N AT O R S AAK

APPLICATIONS
High output power alternators to satisfy the
needs for electrical energy in a wide range
of applications:
• for cars
• for commercial vehicles
• for heavy-duty applications
• for special applications

DESIGN
The alternator is a three-phase 12-pole
synchronous self-excited generator with built-
in rectifier and regulator and cooled by an
external fan. Depending upon the purpose
of the installation, various versions can be
supplied: insulated, marine and other versions
according to special requirements.

Cooling
An integral fan provides effective through cooling
MAIN TECHNICAL DATA of the alternator. Two different fans are used
depending upon the required direction of rotation.
Type AAK

Rotor
Nominal voltage 14V 28V
With regard to the requirements of the installation
and the operating conditions, different protection
Nominal current 45A-80A 35A – 50A
levels are provided for the slip rings and brush
compartment.
Stator diameter 125 mm

Rectifier
Weight ~4.7 kg without pulley
A three-phase bridge circuit with power rectifier
diodes and excitation diodes provides D.C. output
Max. speed 18,000 RPM
currents and excitation of the alternator. It is possible
to use Zener power diodes to protect loads on the
Regulator Built-in or separate
Mono or multifunction vehicle against alternator overvoltages.
Hybrid or microelectronic
monochip technology Regulator
Regulator with brush holder is fitted to the alternator.
Pulleys and drive Different types according to customers'
They are made in thin-film hybrid or microelectronic
end brackets requirements.
technology. With regard to the requirements
of the application they may be monofunction
Terminals Screw and/or blade terminal
or multifunction. The highest quality brushes ensure
long life of the alternator.
Drive end bearings Type 6203 / 6303 / 6304E / 6403-2RS

Brackets - Bearings - Pulleys


Rear end bearing Type 6201-2RS Brackets, bearings and pulleys are made according
to the customers’ requirements. A range of special
Power diodes Rectifier or Zener diodes sealed bearings makes it possible to design
alternators for specific installations, operating
Protection of the slip Protected against access by a wire or in the harshest conditions whilst achieving long,
rings and brushes splashing water (IP 44) maintenance free life.
Protected against ingress of solid foreign
matter and powerful water jets (IP 56) Electrical terminals
Electrical terminals are according to the
Ambient temperature From - 40ºC to + 110ºC customers’ requirements.
A LT E R N AT O R S AAK

CROSS SECTION 1 2 3 4 5 6 7 8 9 10

Pos 1 … Pulley 11
Pos 2 … Drive end bearing
Pos 3 … Fan 12

Pos 4 … Drive end bracket


13
Pos 5 … Stator with winding
Pos 6 … Rotor 14
Pos 7 … Rear bracket

o 125 mm
Pos 8 … Snap rings 15

Pos 9 … Sealing felt


16
Pos 10 … Rectifier with diodes
Pos 11 … Protective cover 17
Pos 12 … Slip rings
Pos 13 … Terminals B+, D+, W 18
Pos 14 … Capacitor
Pos 15 … Rear bearing
Pos 16 … Brush
Pos 17 … Brush holder with voltage regulator
135 mm
Pos 18 … Rubber gaskets

CHARACTERISTICS

I(A) I(A)
80 80A 60
75A
70
65A 50A

60 45
55A 40A
50
35A
45A
40 30

30

20 15
U=const.=13V U=const.=27V
10 To=23ºC±5ºC To=23ºC±5ºC

0 0
0 1000 2000 3000 4000 5000 6000 7000 0 1000 2000 3000 4000 5000 6000 7000

n(RPM) n(RPM)

I (A) at I (A) at I (A) at I (A) at


n ° (RPM) 1800 RPM 6000 RPM n ° (RPM) 1800 RPM 6000 RPM
14V 45A 1000 28 45 28V 35A 1200 15 35
14V 55A 1100 27 54 28V 40A 1450 12 40
14V 65A 1100 30 65 28V 50A 1550 5 50
14V 75A 1250 34 74
14V 80A 1350 29 80

L EX
CONNECTION
B+ B-
D+ B+ B- W D-
DIAGRAMS
REGULATOR REGULATOR
DF D+ DF

Monofunction Multifunction
G

regulator regulator
A LT E R N AT O R S AAK compact

APPLICATIONS
• for passenger cars
• for commercial vehicles
• for heavy-duty applications
• for special applications

F eatures
• high specific power and efficiency
• small dimensions
• low weight
• low noise level
• higher protection against accidental contact
• long life operation

DESIGN
The alternator is a three-phase, 12-pole
synchronous self-excited generator with two
internal fans and built-in regulator and rectifier.
The compact construction and carefully selected
materials assure improved technical
characteristics and long life, service free,
operation even under the harshest conditions
of high and low temperatures, salt spray,
humidity, water, dust, vibrations, aggressive
liquids.
MAIN TECHNICAL DATA Stator
The stator has a three-phase winding on a laminated
Type AAK Compact pack. The selected design and high filling factor of the
stator slots provides improved cooling, low noise and
high output characteristics.
Nominal voltage 14V 28V
Cooling
Nominal current 70A-120A 40A – 60A Two internal fans positioned on the claw poles provide
more effective cooling with lower noise and higher
protection against accidental contact as well as higher
Stator diameter 125 mm output.

Rotor
Weight ~5.3 kg without pulley
Smaller slip rings provide higher brush durability, even
at high speeds. Encapsulated slip rings offer increased
Max. speed 20,000 RPM durability of the alternator.

Rectifier
Regulator Built-in or separate Sandwich construction of the rectifier with press fit
Monofunction or multifunction Zener diodes provides the low temperatures of the
rectifier diodes, high resistance to vibrations and
Microelectronic technology protection of loads on the vehicle against alternator
overvoltages. The installation of the rectifier on the
Pulleys and drive Different types according to customers' outer side of the rear end bracket ensures flexible
arrangement of all types of terminals.
end brackets requirements.
Regulator
Terminals Screw and/or blade terminal The regulator together with the brush holder is
assembled on the rear end bracket. Regulators use
microelectronic technology and are mono or
Drive end bearings Type 6303, 6304E, 62304E multifunction. The highest quality of brushes ensure
long life of the alternator.
Rear end bearing Type 6003 Brackets - Bearings - Pulleys
Brackets, bearings and pulleys are made according to
Power diodes Press fit Zener diodes
the customers’ requirements. A range of special sealed
bearings makes it possible to design alternators for
specific installations, operating in the harshest
Protection of the slip Protected against ingress of solid foreign conditions whilst achieving long, maintenance free life.
rings and brushes matter and powerful water jets (IP 56)
Electrical terminals
Electrical terminals are according to the requirements
Ambient temperature From - 40ºC to + 110ºC of the customers.
A LT E R N AT O R S AAK compact

CROSS SECTION 1 2 3 4 5 6 7 8

9
Pos 1 … Pulley

Pos 2 … Drive end bearing

Pos 3 … Drive end bracket

Pos 4 … Stator with winding


10
Pos 5 … Rotor

o 125 mm
Pos 6 … Rear bracket 11

Pos 7 … Rectifier with diodes


12
Pos 8 … Protective cover
13
Pos 9 … Terminals B+, D+, W

Pos 10 …Rear bearing 14

Pos 11 …Slip rings

Pos 12 …Brush

Pos 13 …Brush holder with voltage regulator


140 mm
Pos 14 …Rubber gaskets

CHARACTERISTICS

I(A) I(A)
120 120A 80

105 70

95A 60A
90 60
85A 55A
80A 50 50A
75
70A 45A
60 40 40A

45 30

30 20
U=const.=13V U=const.=27V
15 To=23ºC±5ºC 10 To=23ºC±5ºC

0 0
0 1000 2000 3000 4000 5000 6000 7000 0 1000 2000 3000 4000 5000 6000 7000

n(RPM) n(RPM)

I (A) at I (A) at I (A) at I (A) at


n ° (RPM) 1800 RPM 6000 RPM n ° (RPM) 1800 RPM 6000 RPM
14V 70A 1000 47 70 28V 40A 1000 23 40
14V 80A 1100 40 80 28V 45A 1100 22 45
14V 85A 1000 47 84 28V 50A 1200 22 50
14V 95A 1100 42 94 28V 55A 1250 21 55
14V 120A 1400 30 115 28V 60A 1400 18 60

CONNECTION DIAGRAM D+ B+ B- W D-
REGULATOR

DF D+
G
A LT E R N AT O R S AAN compact

APPLICATIONS
• for passenger cars and commercial vehicles
with higher electrical demand
• for heavy-duty applications
• for special applications

F eatures
• high specific power and efficiency
• small dimensions
• low weight
• low noise level
• higher protection against accidental contact
• long life operation

DESIGN
The alternator is a three-phase, 12-pole
synchronous self-excited generator with two
internal fans and built-in regulator and rectifier.
The compact construction and carefully selected
materials assure improved technical
characteristics and long life, service free,
operation even under the harshest conditions
of high and low temperatures, salt spray,
humidity, water, dust, vibrations, aggressive
MAIN TECHNICAL DATA liquids.

Type AAN Compact Stator


The stator has a three-phase winding on a laminated
pack. The selected design and high filling factor of the
Nominal voltage 14V 28V stator slots provides improved cooling, low noise and
high output characteristics.
Nominal current 100A-150A 60A – 100A
Cooling
Two internal fans positioned on the claw poles provide
Stator diameter 142 mm more effective cooling with lower noise and higher
protection against accidental contact as well as higher
output.
Weight ~7.3 kg without pulley
Rotor
Smaller slip rings assure higher brush durability, even
Max. speed 20,000 RPM at high speeds. Encapsulated slip rings offer increased
durability of the alternator.
Regulator Built-in or separate
Rectifier
Monofunction or multifunction Sandwich construction of the rectifier with press fit
Microelectronic technology Zener diodes provides for low temperatures of the
rectifier diodes, high resistance to vibrations and
protection of loads on the vehicle against alternator
Pulleys and drive Different types according to customers' overvoltages. The installation of the rectifier on the
end brackets requirements. outer side of the rear end bracket ensures flexible
arrangement of all types of terminals.
Terminals Screw and/or blade terminal Regulator
The regulator together with the brush holder is
Type 6304E, 62304E
assembled on the rear end bracket. Regulators use
Drive end bearings
microelectronic technology and are mono or
multifunction. The highest quality of brushes ensure
Rear end bearings Type 6203 long life of the alternator.

Bearings - Brackets - Pulleys


Power diodes Press fit Zener diodes Brackets, bearings and pulleys are made according to
the customers’ requirements. A range of special sealed
bearings makes it possible to design alternators for
Protection of the slip Protected against ingress of solid foreign specific installations, operating in the harshest
rings and brushes matter and powerful water jets (IP 56) conditions whilst achieving long, maintenance free life.

Electrical terminals
Ambient temperature From - 40ºC to + 110ºC Electrical terminals are according to the requirements
of the customers.
A LT E R N AT O R S AAN compact

CROSS SECTION 1 2 3 4 5 6

Pos 1 … Pulley
Pos 2 … Drive end bearing 13

Pos 3 … Drive end bracket 14


Pos 4 … Stator with winding
12
Pos 5 … Rotor
11

o 142 mm
Pos 6 … Rear bracket
Pos 7 … Rectifier with diodes
Pos 8 … Protective cover 10

9
Pos 9 … Terminals B+, D+, W
Pos 10 …Rear bearing 8

Pos 11 …Slip rings 7

Pos 12 …Brush
Pos 13 …Brush holder with voltage regulator
148 mm
Pos 14 …Rubber gaskets

CHARACTERISTICS

I(A) I(A)
160 120
150A
140A
140 105 100A
130A
120A
120 90
80A

100 75 70A

80 60

60 45

40 30
U=const.=13V U=const.=27V
20 To=23ºC±5ºC 15 To=23ºC±5ºC

0 0
0 1000 2000 3000 4000 5000 6000 7000 0 1000 2000 3000 4000 5000 6000 7000

n(RPM) n(RPM)

I (A) at I (A) at I (A) at I (A) at


n ° (RPM) 1800 RPM 6000 RPM n ° (RPM) 1800 RPM 6000 RPM
14V 120A 1050 78 125 28V 70A 1050 41 74
14V 130A 1050 80 134 28V 80A 1250 39 85
14V 140A 1200 72 145 28V 100A 1250 38 100
14V 150A 1200 74 154

CONNECTION DIAGRAM D+ B+ B- W D-
REGULATOR

DF D+
G
A LT E R N AT O R S A AT

APPLICATIONS
These alternators provide very high output
power and are designed to be built into
applications requiring high consumption of
electrical energy. They were all initially designed
for installation on diesel engines in buses and
some special purpose applications.

DESIGN
The alternators are three-phase, 16-pole
synchronous generators, self-excited by a rotor
consisting of claw poles using protected slip
rings. They have a built-in rectifier and regulator
and are cooled by an external fan. Design
solutions and anticorrosion coatings as well as
specially chosen bearings ensure long life
without maintenance under normal operating
conditions. For operation in extremely hard
conditions - temperature, dust, water - it is
advisable to ventilate the alternator using a
special protection cover on the rear.

Cooling
The alternator has a built-in fan with axial - radial
blades that allow rotation in both directions. It is
MAIN TECHNICAL DATA also possible to use a low-noise fan with specially
shaped blades.
Type AAT
Stator
Nominal voltage 28V A three-phase stator winding with a high filling
factor of the slots and a special method of assembly
Nominal current 75A-140A provide better cooling and high output power.

Stator diameter 165 mm Rotor


The rotor field winding provides excitation of the
Weight ~9.6 kg without pulley for 75A alternator through slip rings. With regard to the
~14.5 kg without pulley for 140A installation requirements, slip rings and brushes are
protected in an enclosed environment sealed against
Max. speed 9,000 RPM dust and water.

Regulator Built-in or separate Rectifier


Monofunction The rectifier stack is a three-phase bridge circuit
Hybrid technology with built-in press fit power and excitation diodes.
Press fit Zener diodes are used to protect alternator
Pulleys and drive Different types according to customers'
and loads on the vehicle against overvoltages.
end brackets requirements

Regulator
Terminals Screw and/or blade terminal
The regulator together with the brush holder is built
into the rear end bracket of the alternator. Regulators
Drive end bearings Type 62306-2RS
are produced in thick-film hybrid technology.
Monofunction versions of the regulator only are
Rear end bearings Type NU 202 available.

Power diodes Press fit Zener diodes Brackets - Bearings - Pulleys


The high quality specially chosen bearings provide
Protection of the slip Protected against ingress of solid foreign long service free life.
rings and brushes matter and powerful water jets (IP 56)
Electrical terminals
Ambient temperature From - 40ºC to + 110ºC Electrical terminals are according to the customers'
requirements.
A LT E R N AT O R S A AT

CROSS SECTION 1 2 3 4 5 6 7 8 9 10

Pos 1 … Pulley 11
Pos 2 … Drive end bearing
Pos 3 … Fan 12
Pos 4 … Drive end bracket
Pos 5 … Stator
13
Pos 6 … Rotor

o 165 mm
Pos 7 … Rear bracket 14
Pos 8 … Rectifier
Pos 9 … Rubber gaskets
15
Pos 10 … Brush
Pos 11 … Brush holder with voltage regulator
16
Pos 12 … Oil seal
Pos 13 … Rear bearing
Pos 14 … Slip rings
Pos 15 … Terminals D+, B+, W
Pos 16 … Capacitor 227 mm

CHARACTERISTIC

I(A)
160

140 140A

120 120A

105A
100
95A

80
75A

60

40
U=const.=28V
20 To=23ºC±5ºC

0
0 1000 2000 3000 4000 5000 6000 7000

n(RPM)

I (A) at I (A) at
n ° (RPM) 1800 RPM 6000 RPM
28V 75A 1000 50 75
28V 95A 950 60 95
28V 105A 900 70 105
28V 120A 1020 78 120
28V 140A 1080 90 140

CONNECTION DIAGRAM
D+ C B- B+ W D-
REGULATOR
DF D+
R
G
A LT E R N AT O R S product requirements form

1. CUSTOMER

Company:

Address: Country:

Responsible person:

Phone: Fax: E-mail:

2. ENGINE DATA
PROJECT
Name: inquiry new project modification
Brief description:

Quantity in next years: 1 st 2 nd 3 rd 4 th 5 th

APPLICATION
cars trucks buses agriculture road industry railway marine
other applications

ENGINE DATA
petrol diesel 2/4 stroke No. of valves
No. of cylinders Compression Displacement Ltr.
Rated output kW Min. speed RPM Max. speed RPM

PREDECESSOR / EQUIVALENT TYPE OF ALTERNATOR


Supplier Type Mark
Drawing Release number

3. ALTERNATOR REQUIREMENTS

ELECTRICAL REQUIREMENTS
Voltage V Current A (1800 min -1 ) A (6000 min -1 )
Power kW Isolated ground NO YES

Electrical connections
B+ type of terminal D+ type of terminal
W type of terminal B- type of terminal
Other connection - terminals

Regulator voltage Ur = V
Regulator: monofunction multifunction
Description of function
A LT E R N AT O R S product requirements form

MECHANICAL REQUIREMENTS FOR ALTERNATOR


Direction of alt. rotation: clockwise counterclockwise both directions
Ratio between engine and alternator: 1:
Type of driving belt/ pulley:
one groove, belt width mm angle
two groove, belt width mm dimension between belt angle
poly V belt, number of grooves dimension between grooves angle
Diameter of the pulley mm Belt line dimension
Type of pulley bearing

DESIGN REQUIREMENTS
Max. diameter: mm Max. length: mm Max. weight: kg

Please draw direction,


Type of installation position of cables,
terminals (back side view)

Other design requirements:

Grade of protection according IP (DIN 40050): IP


Environmental conditions: salt spray high temperature low temperature
humidity others

Mounting requirements: (to specify/sketch) or enclose drawing

Special requirements:
Customer test specification No.:
Safety standards:
Other standards:
Vehicle test or bench test (duration/conditions/number of samples):

Date: Signature: