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Stamford HC-Tech-Manual PDF
Stamford HC-Tech-Manual PDF
1 INTRODUCTION 1
2 GENERAL 2
3 OPERATING PRINCIPLES 5
10 ALTERNATOR RATINGS 19
11 TECHNICAL PARTICULARS 20
1.0 INTRODUCTION
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STAMFORD
BRUSHLESS AC GENERATORS
2.0 GENERAL
2.1 TYPE :
STAMFORD HC4, HC5 & HC6 AC generators are of salient pole, revolving field,
brushless, horizontally foot mounted, single/double bearing type. These ac generators
are available in :
2.2 DESIGNATION
H C 4 4 4 C 2
GENERATOR TYPE HC
FRAME TYPE
NUMBER OF POLES 2, 4 OR 6
CORE LENGTH
NUMBER OF BEARINGS 1 OR 2
H C M 4 3 4 C 2
MARINE APPLICATION
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STAMFORD
BRUSHLESS AC GENERATORS
2.3 CONSTRUCTION :
The Stator frame is fabricated steel which has less weight and better aesthetics.
It is designed to ensure correct distribution of air flow over the stator core and
windings.
The stator core is made of high quality low content silicon steel stampings with
C-4 coating for better welding of core packs. These are oriented 90 deg. after every
one fourth length for better magnetic properties. The slots are skewed to reduce the
tooth ripples in the voltage wave form.
The armature coils are made from dual coated, class 200 copper wire & wound with
a 2/3 pitch.
The 2/3rd pitch winding eliminates the effect of triplen harmonics. This reduces the
voltage distortion and increases the capability of the alternator to cope with non-linear
loads.
The insulation system is class H. Main stator windings are vaccum pressure
impregnated in an unsaturated polyster resin and main rotor windings are wet wound
with epoxy resin. These processes are designed specifically to provide protection
against the harsh environment encountered in the generator applications. Resins are
selected and developed to provide the high build required for static windings and the
high mechanical strength required for the rotating components. The rotating components
can withstand on overspeed of 2250 rpm for three minutes.
The Rotor core is made of high quality low content silicon steel stampings. The poles
carry continuous damper windings to facilitate parallel operation.
End shields are of cast iron construction and are fixed by easily accessible high tensile
bolts.
2.3.7 BEARINGS :
The bearings used are of sealed bearing type. The bearing life is 30,000 hours of
operation and is subject to working conditions and environment. High axial vibration
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BRUSHLESS AC GENERATORS
from the engine or misalignment of the set will also stress the bearing reducing its
life.
2.3.8 SHAFT :
The shaft is made of high quality grade steel. The shaft is liberally designed for
overload & short-circuit conditions.
2.3.11 ENCLOSURE :
IP23 is standard for all industrial generators. The machine is protected against spraying
water i.e. water falling as a spray at an angle up to 600 from the vertical shall have
no harmful effect. Air filters are available as an option for all generators at reduced
rating (5% de-rate).
2.4 BALANCING :
All generator rotors are dynamically balanced to better than Grade 2.5 (BS 6861 :
Part 1) for minimum vibration in operation.
The absence of brush gear and the high quality of AVR design ensure low levels of
interference with radio transmission. Additional RFI suppression kit can be supplied
if required.
The Dip feature helps to reduce the block load coming on the engine & the DWELL
introduces a time delay in the recovery of voltage to allow the engine to have an
improved speed recovery.
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STAMFORD
BRUSHLESS AC GENERATORS
Set Reference
Power
Sense Output
A.V.R.
Exciter
Main Stator Field
(Stator)
Exciter
Main Field (Rotor) Rotor
(Arma-
Rotating Diodes ture)
Mechanical
Rotational
Power Input
I. Here the excitation power is derived from the main output winding. Referring to
figure 1, initially the machine builds up voltage with the help of residual magnetism.
II. The automatic voltage regulator (AVR) will sense this low voltage and compare it
with the set reference voltage level and provides such power as is available from
the main stator winding in order to establish the exciter field.
III. The power from the main output winding is rectified in the AVR and added to residual
voltage level of exciter to produce a greater magnetic field strength. This in turn
increases output voltage from the exciter rotor.
IV. The output from the exciter rotor is rectified by the rotating diodes which adds to
the field strength and increases the output voltage from the main stator.
V. The AVR senses this increase, compares it with the set reference and uses the
increased power from the main stator to further increase the exciter field excitation
as required.
In this way the main stator voltage is progressively built up until the sensed voltage
is the same as the set reference voltage.
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STAMFORD
BRUSHLESS AC GENERATORS
Power
Set Reference
Sense Output
A.V.R.
Exciter
Main Stator Field
(Stator) Permanent
Magnet
Stator
Exciter Permanent
Rotor Magnet
Main Field (Rotor) Field
(Arma-
Rotating Diodes ture) (Rotor)
Mechanical
Rotational
Power Input
II. The permanent magnet produces an output voltage that is only dependant on speed
and is independent of load conditions. This constant output voltage is fed to the
exciter field winding through the AVR.
III. By comparing the main output sensed voltage with the set reference voltage, the
AVR decides on the proportion of permanent magnet machine output to rectify
and feed to the exciter field.
IV. The exciter rotor output would then increase, establishing a strong main field and
therefore a marked increase in main output voltage.
V. The AVR senses and compares voltages and adjusts exciter field excitation until
desired output voltage is developed.
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STAMFORD
BRUSHLESS AC GENERATORS
2) Ability to sustain short circuit current in the event of fault. This presents circuit
breakers enough time to effect a trip to eliminate the fault and provide better
discrimination in the protection of sub-circuits.
3) Since the AVR is supplied from PMG, isolated from alternator output terminals,
the harmonic currents from the load are prevented from passing to the AVR. This
reduces voltage distortion.
4) The process of initial voltage build up is very positive in this system, as residual
magnetism is no longer continually depended upon.
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STAMFORD
BRUSHLESS AC GENERATORS
4) SX 440, SX460 & SX 421 are used in self excited machines and MX 341 & MX 321
are used in Separately Excited Machines.
6) Under frequency protection is set at 97% Hz. The light emitting diode (LED)
indicator, is lit when the generator is running below 97% Hz.
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STAMFORD
BRUSHLESS AC GENERATORS
SENSING 2 3 2 3
ACCESSORIES
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STAMFORD
BRUSHLESS AC GENERATORS
1) AVR used on the machines is imported from Newage International and is of proven
design, reliability and performance. These are uniquely encapsulated against moisture,
sand, salt, humidity and corrosive atmosphere ensuring trouble free operations under
the most demanding conditions. The voltage regulation offered is from 1.5% to 0.5%
depending on the type of AVR used.
2) There are 12 output terminals which are reconnectable to provide output from 190
volts to 440 volts depending on the requirement .Refer to the factory for supply of
reconnectable links.
4) Wave-form distortion on no-load is less than 1.5% .Total harmonic distortion and the
telephone interference is less than 2%.
5) All stators are wound to 2/3rd pitch, which alongwith PMG excitation system and 3
phase rms sensed AVR provides better system performance.
6) Damper winding on poles ensure smooth parallel operation with similar and dissimilar
machines and with the grid. Power factor controller is recommended when balancing
with grid.
7) Liberally rated diodes used in rotating rectifier assembly ensures high reliability.
8) The rotating diodes are protected by a surge suppresser which has the ability to chop
the transients.
5.2 PROCESS
2) Burr free stamping pack construction and file free winding results in excellent quality
of winding and also better machine life.
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STAMFORD
BRUSHLESS AC GENERATORS
6.1 TEMPREATURE
These alternators are designed for an ambient temperature of 400C For marine and
other applications where the ambient temperature is greater than 400C, the alternators
must be de-rated to ensure that the actual temperature does not exceed the specified
maximum.
Outputs are normally quoted at 40 deg. C. These outputs must be multiplied by the
following factors for higher ambient temperatures.
TEMPERATURE MULTIPLIER
( 0C)
45 0.97
50 0.94
55 0.91
60 0.88
6.2 ALTITUDE
Above 1000 m the effectiveness of the air is reduced sufficiently to make de-rating
necessary.
For altitudes above 1000 m outputs must be multiplied by the following factors.
ALTITUDES MULTIPLIER
1,500 0.97
2,000 0.94
2,500 0.91
3,000 0.88
3,500 0.85
4,000 0.82
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STAMFORD
BRUSHLESS AC GENERATORS
2) Air Filters
Under site conditions where the air may be heavily laden with fine dust or sand we
strongly recommend the fitting of inlet air filter. The sizing of these is important to
avoid airflow restrictions and advice should be sought from the works.
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BRUSHLESS AC GENERATORS
7.1 Where a specification exists for any particular load or installation, it is always advisable
to forward a complete copy to the factory for examination. As a result of such an
assessment it is sometimes possible to incorporate design changes to provide a more
economic machine which still meets the specification.
7.2 There are two basic conditions to check when sizing machines. The steady state
Condition, which is mainly concerned with normal operation of the machine within
temperature rise limits; and the transient condition of the machine voltage deviations
when suddenly applying high current loads (e.g. during motor starting). It is essential
that both these conditions are checked as a rating sufficient for the steady state
condition is often not large enough to meet motor starting or voltage dip requirements.
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BRUSHLESS AC GENERATORS
a) Linear Loads
b) Motor Loads (part of linear loads,considered separately)
c) Non-linear Loads.
Examples of linear loads are motor, incandescent lighting and heating loads.
To select the rating of ac generator for linear loads the maximum connected load
and the base load which is always connected has to be considered. In arriving at a
total load figure it is always wise to select the standard rating larger than that
estimated.This despite the fact that all the loads may not be operating at the same
time and hence a smaller machine could have been selected. Future operating
conditions and future growth are very difficult to estimate. An allowance of 15% to
20% excess capacity designed into a set now is a small price to pay compared with
the cost of completely new larger unit that may be required to drive additional loads
in a few years time.
It is the nature of the applied load that dictates the system power factor.
a) The loads which operate at or very close to unity (1.0)power factor include most
forms of lighting, all heating elements, rectifier and thyristor type loads & all domestic
loads which are fractional hp motors (washing machine,refrigerator, etc.)
b) For all remaining load types, some knowledge of operating power factor is required,
which for motors depends a great deal on their size and power rating.
Stamford a.c. generators perform satisfactorily at any power factor in the range of 0.8
p.f. lag to unity p.f. Operation at leading and lagging power factors (below 0.8)demands
a derate and reference to the factory must be made.
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STAMFORD
BRUSHLESS AC GENERATORS
During the starting of an induction motor, a very large current is demanded from the
power source, which is known as the starting or locked rotor current. For sizing
alternators which have to cater to motor loads, the following guidelines can be referred
to.
Over a period of time the loads applied to AC generators have become more complex
and more care has to be exercised in the sizing of the generators to ensure
satisfactory performance.
8.6 CHARACTERISTICS OF NON LINEAR LOADS
a) A non linear load is one in which the load current is not proportional to the
instantaneous voltage. Often the load current is not continuous.
b) These are essentially electronic loads such as Computers, UPS equipments and
variable speed motor drives.
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STAMFORD
BRUSHLESS AC GENERATORS
a) Non linear loads generate harmonics in their current waveform which in turn leads
to distortion of the ac generator waveform. Depending upon the degree of voltage
waveform distortion this can lead to instability of the excitation system and impact
on other loads being supplied by the generator.
b) UPS & Telecom load Non linear load should not exceed
controlled by a 12 Pulse Thyristor 90% of alternator rating
bridge plus a filter.
The above percentage figures are guidelines. There may be a problem with electronic
load trying to cope with distorted waveform if distortion levels are unacceptable to
the load.
c) What is the maximum acceptable level of voltage distortion the Non-linear load
can accept?
e) If Non-linear load power requirement is stated in kW, then some guidance regarding
operating power factor & system efficiency is required to establish the alternator
load.
With the information guidance should be sought from the factory regarding alternator sizing
for compatible equipment operation.
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STAMFORD
BRUSHLESS AC GENERATORS
Remember : The generator droop kit can control only the kVAr sharing and
circulating current. The sharing of kW load is determined by engine governors.
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STAMFORD
BRUSHLESS AC GENERATORS
Stamford machine can be paralleled with other make machines but with neutrals not
connected. On the other hand, two Stamford machines with similar winding pitch may
be paralleled successfully with their neutrals linked. If during commissioning, it is found
that neutral currents are flowing, then this will be a product of the characteristics of the
load being supported on the local network. Therefore, neutral interconnections is an issue
of system design.
The mains voltage waveform is very close to a sinewave and has a very few harmonics.
To parallel successfully with the neutrals linked, the generator is required to have a good
line-line and line-neutral waveform. With 2/3 pitch the line-neutral waveform is excellent
and hence paralleling with mains will have no major problems.
For parallel operation with mains, we recommend our Power Factor Controller. It has
facility for adjusting the voltage of the generator to the fluctuating mains voltage for
successful operation. It also improves the power factor of the system thereby reducing
utility charges.
A loss of generator excitation during parallel operation will result in heavy circulating
currents. The Stamford Excitation Loss Module monitors the generator AVR output
and signals any sustained interruption to an integral relay to initiate an indication / alarm.
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BRUSHLESS AC GENERATORS
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BRUSHLESS AC GENERATORS
NOTES :
A) THE VOLTAGE REGULATION CLAUSES ARE NOT APPLICABLE FOR NON - LINEAR
LOAD AND UNBALANCED LOAD CONDITIONS.
C) THESE FIGURES ARE FOR GENERAL GUIDANCE ONLY AND ARE NOT TO BE TAKEN
FOR INSPECTION AND HENCE FOR ACCEPTANCE OR REJECTION.
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