ALTERNATOR TRAINING

ADVANCE LEVEL

TRAINING DEPARTMAN
IHSAN YAVUZ ERMIS
ALTERNATOR TRAINING

Electromagnetic Field :
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Electrical Definations:

 Resistance, Unit : Ohm (R)

• Resistance is a measure of the degree to which
an object opposes the passage of electric current
• Measurement Device : Ohmmeter

 Voltage, Unit : Volt (V)

• Voltage is the difference of electrical potential
between two points of an electrical network
• Measurement Device : Voltmeter

 Current, Unit : Ampere (A)

• Moving electrons by voltage and flowing electrons
V  IxR
• Measurement Device : Ampermeter
• 1 Ampere = 6,28x1018 electron /s
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Faraday’s Law :

Any change in the magnetic field of a coil of wire will cause a voltage
(emf) to be "induced" in the coil. No matter how the change is produced, the
voltage will be generated. The change could be produced by changing the
magnetic field strength, moving a magnet toward or away from the coil, moving
the coil into or out of the magnetic field, rotating the coil relative to the magnet,
etc.
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• Alternating Current (AC) : • Direct Current (DC) :

AC current is changed direction DC current is not changed
and strenght by the time. direction and strenght by
the time.
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Magnetic field on the windings induce alternating

(AC) voltage in main stator.
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When the magnetic field

around a conductor changes, a
current is induced in the
conductor. In a alternator, a
rotating magnet called the rotor
turns within a stationary set of
conductors wound in coils on
an iron core, called the stator.
The field cuts across the
conductors, generating an
electrical current, as the
mechanical input causes the
rotor to turn.

Permanent Magnetic Field

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Voltage regulator senses

induced voltage in main Rotating
Diodes

stator to take a referance.

Sensed voltage
Excitation
Voltage DC

compares regulator setting Excitation

values (400 V AC, 50Hz). Stator

Excitation voltage Excitation

Rotor

realize excitation stator via

excitation toes of regulator
according to the difference Automatic
Voltage Referance
Regulator Points

Set Values
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Diodes rectify DC
voltage to induced AC
voltage in excitation
AC
LOAD

rotor to increase
permanent magnet in Main

main rotor.
Rotor

Inputs of
Diodes
Excitation
Rotor
Voltage AC Rotating

Excitation rotor Output of

Diodes Main
Diodes

voltage realizes main Rotor

Voltage DC

rotor windings which

rectified DC voltage. Excitation
Stator
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 Sine wave current in  Vector sum of the

each of the coils magnetic field vectors of
produces sine varying the stator coils produces a
magnetic field on the single rotating vector of
rotation axis. Magnetic resulting rotating
fields add as vectors. magnetic field.
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Main Stator Coils in Slots (section) Main Stator Core

(section)
4 Pole Main Rotor

Air Gap

 1 Cycle
S

N SHAFT N

 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
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Main Stator Core

Main Stator Coils in Slots (section)
(section)
4 Pole Main Rotor

Air Gap
1 Cycle

 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.

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Main Stator Core
Main Stator Coils in Slots (section)
(section)
4 Pole Main Rotor

Air Gap

N
1 Cycle

SHAFT

S
S

N
 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.
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Alternators Which We Use in AKSA :

(standard)
(standard)

(Aksa alternator, standart APD series)

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Coupling Terminal Box

disk

A.V.R.
Stator

Main
Rotor

Rotating
Excitation Rotor Diodes Plate
and Varistor
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Terminal Box (Mecc Alte ECO 34)

Neutral
Point

Paralleling
Transformer

Output
Points

U- V- W

RFI
Suppressor

A.V.R.
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Terminal Box (Stamford P7 Series) :

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Main Stator :
Main stator which is made of high quality siliceous
laminations is mounted by means of supporting ribs in a sheet steel
body.

Main stator grooves and main rotor poles are designed to

minimize distortion on the waveform. Main stator windings have a
shortened pitch to reduce the harmonic effects on the waveform.
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Main Rotor :
The rotor is salient-pole type. Damper windings are
placed into the rotor as a standard feature for parallel work and
unbalanced loads. Fan, the main rotor, excitation rotor and the
rotating diodes are fitted to shaft . The entire rotor is dynamically
balanced.

2 Poles 4 Poles

N S
MİL MİL
N N
S
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Main Rotor Winding - Coil Group Connections :

ANTICLOCK

D.C ınput
from main S
rectifier

CLOCK CLOCK
N N

ANTICLOCK

 The Rotor coils are connected in Series (4 Pole Rotor shown).

 Each coil is reversed to the adjacent coil, producing the required polarity
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Automatic Voltage Regulator (AVR) :

This is the most important element of the alternator. At

asymmetrical loads, the voltage regulator senses three phases as a
reference therefore maximum voltage asymmetry is 5%. Electrical and
thermical tests are applied before mounting on the alternator. The output
voltage could be adjusted manually by a potentiometer.

Alternator Reference LOAD

(Sensing)

Voltage
Regulator

Setting
Values
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Automatic Voltage Regulator (AVR) :

To remotely regulate the voltage there are terminals for

potentiometer connection.

MeccAlte DSR Electronics

Voltage Regulator
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Automatic Voltage Regulator (AVR) :

 Mecc Alte
 DSR (latest version)
 SR7 (old version)
 UVR6 (old version)

 Stamford
 SX 460 SX 440 SX 421 SA 465
S : Self excited
 MX 341 MX 321 MA 325
M : Permanent Magnet Generator
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MeccAlte DSR Voltage Regulator Technical Features:

 40-270 V AC supply.
 Full digital controlled regulator (software, PC connection).
 RS232 and RS485 serial communications interface.
 Maximum continuous output current : 4Adc.
 Output voltage regulation: ± 1
 Voltage recovery time within ± 3% of the value set, in less than 300
msec.
 “Sensing” of voltage measurement: 70÷280 Vac.
 Analogical remote control of output voltage is possible through external
voltage (0÷2Vdc) or with a 10 Kohm linear potentiometer.
 Single phase sensing.
 Overvoltage and undervoltage alarms.
 Transient overvoltage during start up: less than 5% of nominal voltage.
 VOLT, STAB, AMP and Hz can be set with trimmers, 50/60Hz through a
jumper, all parameters can be programmed via software.
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Mecc Alte SR7/2 Voltaj Regulator Setting Potentiometer :

Voltage
Setting

Stability
Setting

Factory Settings
(Low speed and
over load)
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Mecc Alte SR7/2 Voltage Regulator Terminal Connections :

Terminal 1 : Excitation windings negative (-) toe.

Terminal 2 : It should bridge terminal 3 If SR7/2 regulator supply will be
lower then 160 V AC.
Terminal 3 : Excitation windings positive (+) toe and regulator supply.
Terminal 4 : Regulator reference voltage.
Terminal 5 : Common toe for regulator supply, regulator reference voltage
and external potentiometer connection.
Terminal 6 : To bridge terminal 5 for 60 Hz.
Terminal 7 : External potentiometer connection.
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Stamford SX440 Voltage Regulator Technical Features :

 Supply voltage 170-250 Vac

 Frequence 50-60 Hz nominal
 Output voltage max. 90 Vdc
(207 Vac input)
 Output Current 4 A DC
(max. 10 seconds 6 A DC)
 Regulation ±%1
 Operation Temp. -40°C - +70°C
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Stamford MX321 Voltage Regulator Terminal Connections :

Volts:
Setting generator output voltage.
Stability:
Keeping from voltage oscillation, setting steady
state time .
Stability Selection:
To provide suitable voltage transient.
UFRO:
Setting underfrequence protection border.
Frequency Selection:
Providing for suitable operation of UFRO
protection.
Droop:
Enable voltage droop (5 % on full load).
Trim:
To provide regulator input and accessories uotput.
Exc Trip :
Over excitation cutting level (5Vdc - %5, 8-15 s
delayed).
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Stamford MX321 Voltage Regulator Terminal Connections :

DIP:
Setting frequence-voltage curve.
Over/V:
Shuting down excitation voltage When
İnput reference voltage to AVR faults
(Between terminal E1-E0; 300 Vac, 8-15s
delayed).
I-Limit:
Maximum short circuit current.
Dwell:
Voltage tidy up time after on full loaded.
RMS:
Loading.
RAMP:
Setting to reach nominal value of output
voltage by cranking. Factory setting is 3
seconds and it’s enough for many
applications.
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External Voltage Potentiometer Connection :

• Voltage potentiometer can be

connected terminal 1 and 2 of all
AVR for Stamford alternator.
• Normally those terminals are
bridged. Remove this bridge when
the potentiometer connected.

Stamford MX321 Voltage Regulator

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Rotating Diode Plate :

Ac voltage is rectified DC voltage to set the permanent
magnet on main rotor via rotating diodes plate which induce
excitation rotor.
Rotating diode plate is partitioned positive and negative
plate and there are 3 diodes both plates (total 6 diodes).
Rotating Diode Plate Elements :

1. AC Input
2. Rectifier Plate
3. Diodes – 3 x Negative
4. Diodes – 3 x Positive
5. Varistor
6. DC Output to Main Rotor
7. Plate
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Varistor :
Varistors (VDR’s) are a mix of carbon materials that are a
high resistance until subjected to a high pressure.
They then becomes a low resistance path to bleed away
excessive pressure by allowing lots of amps to momentarily flow
through the VDR, which has become a momentary low resistance
path.
This means that the rating of the device based on it only
being asked to conduct for very short period of time and very
intermittently. A VDR that is continually 'clipping‘ excessive
voltages will get hot and fail.
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Excitation Stator and Rotor:

Excitation stator is provided to

induce magnet for excitation rotor by DC
signal via voltage regulator (10-15 V).

On excitation rotor AC voltage is

rectified DC voltage via rotating diodes
plate and varistor. Thus DC Current is
induced for permanent magnet for main
rotor.
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Excitation Rotor & Main Rectifier Assembly :
Wound Exciter Rotor
W U
AC Input
connections Rectifier Assembly

V
SHAFT
SHAFT V
DC Output
connections

W
 The Rectifier assembly is mounted on Exciter Rotor Core, (drive end side).
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Exciter Rotor & Main Rectifier Connections :

Exciter Rotor 3 Phase
with Internal Star Point

SHAFT

 Each phase is connected to a positive and negative Diode

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Main Rotor Connections to Main Rectifier :

Main Rectifier Main Rotor

SHAFT D.C

 The rectifier output is fed to the main rotor windings

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Voltage Regulator Supplying :

PMG
• Provides a separate fixed source impedence
power to AVR & exciter field that is isolated from
the generator output and is not influenced by
external load conditions.
• The isolated PMG power supply of the excitation
system allows the generator to meet low EMI /
RFI suppression levels to meet MIL-
STD.461C&VDE Class K.
• PMG provides constant power to supply manual
voltage control of the generator & to supply
overvoltage , overcurrent & over excitation
protection circuits.
•Stamford and Leroy-Somer alternators have got
PMG system which we use.
 ALTERNATOR TRAINING

Voltage Regulator Supplying :

AREP (Auxiliary Winding System)
It is auxiliary windings system to induce AC voltage to supply AVR
which is inserted the main stator windings.
Auxiliary windings are thin section. Resistance is lower than main
stator windings.
Mecc Alte alternator has got AREP windings system which we use.

Shunt
AC voltage is provided directly by main stator windings to
supply AVR.
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Voltage Regulator Supplying :

When to choose PMG or AREP :

 Whole installation with several circuits

 Power cut forbidden
 High rate of distorting loads.
 Starting 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 alternator
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Load Effect of PMG, AREP and Shunt Systems :

OVERLOAD OR SHORT CIRCUIT

ON THE INSTALLATION

AREP PMG AREP OR PMG

THE ALTERNATOR CONTROLS THE
SITUATION
DURING 10 SECONDS
THE DEFFECT IS RELEASED
THE BREAKER TRIPS

- THE POWER SUPPLY IS MAINTAINED

SHUNT
SHUNT
THE ALTERNATOR DOES NOT HOLD
THE SITUATION
DESENERGIZING OF THE ALTERNATOR

- THE POWER SUPPLY IS CUTTEN

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Alternator Windings Heater (Optional) :

Humidity can be reduced isolation resistance on alternator
windings. In that case heater have to insert the windings for
protection.

Heater
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Bearing :
•Bearing is provided to rotate coupled components of
alternator mandrel (main rotor, excitation rotor, PMG rotor,
rotating diodes, etc.) by stability.
•All standard alternators are single bearing that we use in
AKSA.
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Fan and Airconditioning :

• Alternator windings warme up and by which induce current inside (J=I2Rt).
Warmed windings have to be cooled for efficiency. Fan is used for cooling
system.
• Cooling has to be realized for protection of alternator windings. Therefore
don’t close up air intake and drop ball places.
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Thermic Protection Components :

• Thermic sensors use to protect the warmness of windings in alternator (and

in electrical motors).

Bimetal Contact

PTC Thermistor

PT100 Thermic
Resistor
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RFI Suppressor :
• RFI (Radio Frequency Interference)
is noise vibration in alternator
windings because of magnetic field
(>1 kHz).
• Filter with condenser is used to
reduce the noises.
• Standards :
BS EN 50081-50082
VDE 0875
BS 1597
MIL 461
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Paralleling Transformer (Optional) :

• Paralleling transformer is used for syncronous operation

with other alternators and also with the mains.
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Bloc Diagram For Alternator with PMG :

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Operation of a PMG Generators :

PMG
Power A.C Sensing
A.V.R
Supply Supply From
To A.V.R Main Stator
Main Stator
Exciter
Rotor
& Stator Coupling Discs

Main Rotor
Main Rotor Shaft

PMG
Rectifier
Bearing Fan
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Operation of the Self Excited Generator :

D.C Output A.C Power &

From A.V.R A.V.R Feedback Signal
Into (Sensing)
Exciter Stator From Main Stator
Main Stator
Exciter
Rotor
& Stator Coupling Discs

Main Rotor
Main Rotor Shaft

Bearing

Rectifier
Fan
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Auxiliary Winding System (AREP) :

AC Output

AC Volt Referance

AC Supply to AVR

Auxiliary Auxiliary
Main Stator Winding
AC 3 Stator
Phases

Rotating Auxiliary
Main Rotor Diodes Rotor

Auxiliary
Main Stator Stator
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Block Diagram For Alternator With Transformer :

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Mains – Generator Voltages :

• Mains in Turkey ;
Phase - Neutral : 220 V AC
Phase - Phase : 380 V AC
Frequence : 50 Hz

• During the generator (or transformer) voltage selection, It has to

be rate of 5% voltage difference between operating voltage (380 V
AC) and generator nominal voltage (400 V AC). For our generators ;
Phase - Neutral : 231 V AC
Phase - Phase : 400 V AC
Frequence : 50 Hz
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Generator Operation Powers :

GENERATOR OPERATION POWERS ACCORDING TO

ISO 8528-1 STANDARDS:

 Operation On Standby Power

 Operation On Prime Power
 Operation On Continuous Power
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Generator Operation Powers :

 Standby Operation
(Operation on limited time) :

• This genset operation is used variable loads.

• Load Measure: 110% (1 hour rate of 10% over
load per 12 hours).
• Annual Operation Time : 500 hours
• Application : working centerum, hotels, hospitals,
housing estate, resting places, factories and other
requested stand-by application places.
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Generator Operation Powers :

 Prime Operation
(Operation on unlimeted time) :

• On unlimited time, maximum power from

generator for variable loads.
• Load Measure: 90%
• Annual Operation Time: Unlimited
• Application: Industrial and commercial
companies, devoloping companies , cogeneration
applications, rental and marine gensets.
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Generator Operation Powers :

Continuous Operation :

• On unlimited time, continuous power via

generator.
• Load Measure: 80%
• Annual Operation Time: Unlimited, continuous.
• Application: Continuous base load, mains,
cogeneration, parallel operation.
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Generator Operation Powers :

Operation Operation Duration (Annual) Mains

Type Power
Standby %110 500 hours (max.) Available

Prime %90 Unlimited Available

Continuous %80 Unlimited Not

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Power Quality :
•Acceptable values for harmonic distortions according
to IEC 519-1992 standard;

For Voltage (V) :

3% THD (total harmonic distortion)

For Current (I) :

5% THD (total harmonic distortion)
•More than limited harmonic distortions will be
effected big problems and sacrifices.
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Alternator Lifetime :
 At normaly conditions, alternator lifetime is
approximately about 100.000 hours for
continuous operation
 But ;
• Over current
• Unbalance loads
• Operation on low Cos (power factor) loads
• Over ambient temperature
• Harmonics (because of warmness)
• Less air-condition
• Operation on pulverulent places
• Humid places

will be effected shorter than normaly.

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Efficiency Of Alternator :
Efficiency = Output power / Input Power = kWe / kWm
 Alternator Losts
 Iron lost (Hysterysis and Eddy current)
 Copper lost (Because of windings)
 Friction lost (ballbearing)
 Efficiency of alternator depends on current of load.
 Efficiency of alternator depends on power factor of
load.
 Efficiency is increased if Cos will increase.
 Efficiency is reduced if Cos will reduce.
 Efficiency of alternator is approximately about ;
 For 500-1500 kVA %90-97
 For 0-100 kVA %85-93
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Voltage Unbalance Rate:

 Voltage unbalance is rated the biggest of 3 phases output
voltages of alternator (U,V,W) and average output voltage.

 For example;
Output voltages of alternator are about 236, 229, 225 volts;
 ALTERNATOR TRAINING

Effecting Alternator Of Voltage Unbalance :

• Because of voltage unbalance, A small magnetic field is induced on
alternator windings which is direct opposite main magnetic field.
• Voltage unbalance effects to warm windings up.

Example Calculation :
(Voltage Unbalance)2
Temp. Boost = Nominal Temp x 1 + 2
100

(2,61)2
Temp. Boost = 80C x 1+2 = 80C x 1,136
100

Temp. Boost = 90,9 C

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Setting Voltage Unbalance With “STAB” Potentiometer :

Genset Voltage
Unstable

Critical

Good

Slow

No Load Full Load

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Cos Values Of Electrical Loads :

 Electrical Heater 1

 Incandescent Lamp 1

 3 Phases Motors 0,7-0,9

 Fluorescent Lamp 0,3-0,5

 Neon Lamp 0,4-0,5

 Welder Machine 0,4-0,8

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The Power Triangle :

There are 3 types of electrical powers :

Apparent Power (S, VA)

True Power (P, W)
Reactive Power (Q, VAR)
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Electrical Power Formulas:

 Apparent Power (S, kVA)
 The inductor does not use any true power. However, to the generator, the
inductor “appears” to be consuming power because there is an opposition to
current (inductive reactance) and voltage drop across it.
 The generator power is apparently used by the inductor.The total power used
by the inductor and resistor is called appropriately. Apparent Power.
 Apparent power is measured in Volt-Amperes (VA) to distinguish it from true
power.Apparent power for an inductive circuit can be found by multiplying the
total current by the applied voltage;

Q (kVAr) S  3  UI

P (kW)
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Electrical Power Formulas:

 True (Active) Power (P, kW)
 Inductance and resistance characteristics are both present in industrial motors
which consist of many coils of wire.
 The coils cause current to lag voltage as in an inductor and because of coil
length, the motor also has resistance.
 AC generator is used to provide power to a motor. The resistor is the only
component that comsumes power.
 The power used by a resistor is called True Power.

Q (kVAr) P  S  Cos

P (kW)
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Electrical Power Formulas:

 Reactive Power (Q, kVAR)

 We know that reactive loads such as inductors and capacitors dissipate zero
power, yet the fact that they drop voltage and draw current gives the
deceptive impression that they actually do dissipate power. This “phantom
power” is called reactive power, and it is measured in a unit called Volt-Amps-
Reactive (VAR).

Q (kVAr) Q  S  Sin

P (kW)
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Example Calculation For Electrical Powers

 We will calculate full load current for 100 kVA

gen-set at Cos=0,8 and Cos=1 ;

S  100kVA

Q (kVAr)
S  3 U  I
P  S  Cos

P (kW)
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Example Calculation For Electrical Powers

 Firstly we should calculate active power output
of gen-set (Cos=0,8 for gen-set and it’s
constant).

 Following that ;

P  S  Cos  P  100  0,8  P  80kW

CosCos=0,8
For  0,8 için;
P  3  U  I  Cos
P 80000
I I   I  144,5 Amper
Ampere
3  U  Cos 3  400  0,8
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Example Calculation For Electrical Powers

P  80 kW idi..
ForCos
Cos  1 için;
 =1
P  3  U  I  Cos
P 80000
I I   I  115,6 Amper
Ampere
3  U  Cos 3  400 1
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Calculation For Pole Number :

 Hz : Frequence
NK
Hz   N : Engine speed (rpm)
120  K : Pole number
Example :
We will calculate alternator pole number at 1500 rpm of
engine speed.

NK 120  Hz 120  50

Hz  K  K  K  4 Kutuplu
poles
120 N 1500
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Suitable Generator Selection

 A gen-set for 1000 kVA will supply a load for 900 kVA and
Cos = 0,5 . We will calculate that; is it suitable power of
generator or not? (For all gen-set; Cos = 0,8 constant).

 At the first we should calculate active power and reactive

power both gen-set and load. Following that;

For Gen-Set : Sgen = 1000 kVA Cos φ = 0,8

For Load : Sload = 900 kVA Cos φ = 0,5

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Suitable Generator Selection

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Suitable Generator Selection

 Suitable Generator Selection :

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Voltage and Engine Speed Graph :

• Alternator output voltage is rate of %75 at engine speed
rate of %75.
• Alternator output voltage is rate of %10 at engine low
speed

• This graph is from

MeccAlte alternator.
 ALTERNATOR TRAINING

Windings Connections For 12 Lead Alternators :

We use difference connections on alternator to provide difference voltages by
easily. Accordingly possibility 115/200/230/400 Volts 50Hz on 12 lead
alternators.

 Series Star  Parallel Star  Series Delta

 For 3 Phases  For 3 Phases  For 3 Phases
Sysytems, Sysytems, Sysytems,
 400 Vac (L-L),  200 Vac (L-L),  230 Vac (L-L),
 With neutral,  No neutral
 With neutral, 115 Vac (L-N)
230 Vac (L-N)
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Windings Connections For 12 Lead Alternators :

 Parallel Delta  3 Phases Zig-Zag

 For 3 Phases  For 3 Phases Sysytems,
Sysytems,  346 Vac (L-L),
 115 Vac (L-L),  With neutral.
 No neutral,  Alternator output power
multiple 0,866 (346/400)
 ALTERNATOR TRAINING
Windings Connections For 12 Lead Alternators :
 Single Phase Parallel Zig-Zag
 For Single Phase Sysytems,
 230 Vac (L-L),
 With neutral,
 Usually this connection uses
in Europe’s countries.
 Double Delta
 For Single Phase Sysytems,
 230 Vac (L-L),
 With neutral,
 Usually This connection uses
in Asia’s and America’s
countries. This is the same
connection type of single
phase parallel zig-zag.
 ALTERNATOR TRAINING

Alternator Electrical Drawing :

Excitation Uncontrolled 3 Phases Main Main
Excitation
+ Stator Rotor Bridge Rectifier + Stator
U
Rotor

VDC VARİSTOR
VDC V
- - W
U
Reference
AVR V
W Points

170-250 V AC (PMG, AREP, Shunt)

Voltage Regulator Supply

PMG Stamford, Leroy-Somer

AREP Mecc Alte
 ALTERNATOR TRAINING

IP (Ingress Protection) Code:

 The International Protection code, sometimes called the Ingress

Protection code, classifies the protection given by an enclosure
against the touching of live parts, contact with moving parts and
protection against the ingress of solid bodies.
 It additionally specifies protection against the harmful ingress of
liquids. Two digits are used to describe its protection rating,
called the IP code.

 IP X Y
• IP : Ingress Protection
• X : 1. Number (0-6)
• Y : 2. Number (0-8)
 ALTERNATOR TRAINING

Protection Class According to DIN 40050 Norm:

1.Number
Protection from solid object
 0 : Non protected
 1 : Protected against solid object greater than 50 mm
 2 : Protected against solid object greater than 12 mm
 3 : Protected against solid object greater than 2,5 mm
 4 : Protected against solid object greater than 1,0 mm
 5 : Dust protected
 6 : Dust tight
 ALTERNATOR TRAINING

Protection Class According to DIN 40050 Norm:

2.Number
Protection from moisture
 0 : Non protected
 1 : Protected against dripping water
 2 : Protected against dripping water when tilted up to 15°
 3 : Protected against spraying water
 4 : Protected against splashing water
 5 : Protected against water jets
 6 : Protected against heavy seas
 7 : Protected against effect of immersion
 8 : Protected against submersion
 ALTERNATOR TRAINING

ISOLATION CLASS OF INSULATOR MATERIALS

ACCORDING TO VDE 0530 STANDARD:

• CLASS “H” ISOLATION :

Allowable maximum temperature is about
125°C.

• CLASS “F” ISOLATION :

Allowable maximum temperature is about
105°C.
 ALTERNATOR TRAINING

Before The Maintenance :

 Before any cleaning, lubrication or

maintenance operation, ensure that
the genarator is stationary and
disconnected from the power
supply
 The people in charge of the
handling must always wear work
gloves and safety shoes
 Do not operate the generator with
protective covers, access covers or
terminal box covers removed.
 Disable engine starting circuits
before carrying out maintenance
 ALTERNATOR TRAINING

Alternator Maintenance :

Ballbearing Lifetime :
For the maintenance-free ball bearings
approximately 30.000 hours
For the lubricatable ballbearings approximately
40.000 hours

Lubricating :
Lubricating components should to be cleanly.
Using the suitable oil.
Operate the alternator and shooting out the
excess oil.
 ALTERNATOR TRAINING

Checking The Windings :

 Resistance Test
• According the alternator manual values;
measuring and comparing windings resistance
of the main stator-rotor and excitation stator-
rotor.

 Insulator Test
• Measure main stator-rotor and excitation
stator-rotor with the megger (1MOhm).
• Before test remove all connections of the
AVR.
• During the test 500 V AC effect the windings.
 ALTERNATOR TRAINING

Follow The Suggestions Below For Troubleshooting :

• Study the problem thoroughly before acting.

• Refer to the alternator system diagrams.
• Check the control unit and all cable connections
• Do the easiest and most logical things first.
• Find and correct the cause of the problem.
 ALTERNATOR TRAINING

Troubleshooting
• Alternator does not excite ?

Type of Troubleshooting Solving the trouble

Faulty fuse Change the new fuse

Low permanent voltage Increase speed 15%.
No permanent voltage Shock the main rotor by
polarity.

Shocking application
 ALTERNATOR TRAINING

Troubleshooting

• Low voltage at no load ?

Type of Troubleshooting Solving the trouble

Voltage potentiometer is Set the voltage potentiometer
out of balance
Regulator is protected Check engine speed
Faulty windings Check the windings
Faulty regulator Change the new regulator
 ALTERNATOR TRAINING

Troubleshooting

• High voltage at no load ?

Type of Troubleshooting Solving the trouble

Voltage potentiometer is Set the voltage potentiometer
out of balance
Faulty regulator Change the new regulator
 ALTERNATOR TRAINING

Troubleshooting
• Normal voltage at no load, than lower voltage at loaded.

Type of Troubleshooting Solving the trouble

Regulator is protected
Faulty regulator
Faulty diodes
Current too high, power factor
lower than 0.8, speed lower than
4% of rated speed.
Change the new regulator
Check diodes

Diode Testing
 ALTERNATOR TRAINING

Troubleshooting

• Normal voltage at no load, than higher voltage at

loaded

Type of Troubleshooting Solving the trouble

Faulty Regulator Change the new
regulator
 ALTERNATOR TRAINING

Troubleshooting

• Unstable voltage ?

Type of Troubleshooting Solving the trouble

Unbalance engine speed Set the engine speed

Faulty regulator Change the new regulator

Stability potantiometer is Regulate stability of regulator by

out of unbalance acting on “STAB.” potentiometer.
 ALTERNATOR TRAINING

Troubleshooting

• Abnormal Noises ?

Type of Troubleshooting Solving the trouble

Faulty ballbearings Change the new ballbearings

Unstuck assembly Check the assembly bolts. If

it needs, substitute bolts
 ALTERNATOR TRAINING

THANKS
QUESTIONS

ANSWERS