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GENERATOR SYSTEMS
Contents
Generator Systems................................................................. 1
Generation System Basics................................................... 2
Main Generator Components ........................................... 2
Magnetic Field and Voltage ............................................. 4
Phase and Voltage ......................................................... 5
Generator Design ............................................................... 6
Rotor ............................................................................ 6
Amortisseur Windings................................................. 6
Salient Pole Rotor....................................................... 6
Non-Salient Pole Rotor ................................................ 6
Permanent Magnet Rotor ............................................ 7
Stator ........................................................................... 7
Windings ................................................................... 9
Insulation Systems ....................................................... 11
Rotor Insulation........................................................ 12
Stator Insulation Combinations .................................. 12
Insulation Life .......................................................... 14
Coil Connections .......................................................... 17
Generator Features and Attachments ............................. 19
Bearings .................................................................. 19
Space Heaters ......................................................... 20
Ingress Protection (IP)............................................... 20
Physical Data............................................................... 21
Nameplate ............................................................... 22
NEMA & IEC Design Considerations ............................... 23
Temperature Rise ..................................................... 23
Maximum Momentary Overloads................................ 24
Maximum Deviation Factor........................................ 25
Telephone Influence Factor (TIF) ................................ 25
Single Frequency Weighting Short Circuit
Requirements........................................................... 26
Overspeed ............................................................... 26
Generator Performance Characteristics ............................... 27
Rated and Per Unit ....................................................... 27
Efficiency ................................................................ 27
Fault Current/Short Circuits ........................................... 28
Reactance ............................................................... 31
Transient Reactance (Xd).......................................... 32
Sub-Transient Reactance (Xd)................................... 34
Synchronous Reactance (Xd) ..................................... 36
Negative Sequence Reactance (X2) ............................ 37
Zero Sequence Reactance (Xo) .................................. 37
Harmonics & Distortion..................................................... 39
Miscellaneous Terms ........................................................ 43
Overspeed Capability ................................................ 43
Heat Dissipation ....................................................... 43
Derating .................................................................. 43
Generator Limits .............................................................. 44
Exciter & Regulator Characteristics and Performance ........... 45
Excitation System ........................................................ 45
Self-Excitation ......................................................... 46
Permanent Magnet Excitation .................................... 46
Voltage Regulation ....................................................... 46
Performance ............................................................ 49
Generator Voltage Specifications ............................... 50
Frequency Sensing ................................................... 51
Type ....................................................................... 52
Foreword
This section of the Application and Installation Guide generally describes
Generator Systems for Caterpillar engines listed on the cover of this
section. Additional engine systems, components and dynamics are addressed
in other sections of this Application and Installation Guide.
Engine-specific information and data is available from a variety of sources.
Refer to the Introduction section of this guide for additional references.
Systems and components described in this guide may not be available or
applicable for every engine.
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Generator Systems Application and Installation Guide
Generator Systems
Electricity is a useful source of energy because it is versatile; much more
versatile than mechanical energy. It can be used for a variety of tasks, such
as lighting, heating and rotating electrical machinery and it can be used in a
variety of locations, such as offshore oilrigs, natural gas fields, remote areas
and urban confines.
Caterpillar generators convert the mechanical energy of an engine, or
prime mover, to electricity. The well-proven, innovative designs of Caterpillar
generators have lead to several highly reliable lines of generators used in
electric power generation applications worldwide. All Caterpillar electric
sets use AC generators. The AC generator, also called an alternator,
converts mechanical energy to electrical energy and acts as a voltage
source for the load.
This module describes basic concepts involved in the various Caterpillar
generator designs. It addresses basic electrical generation concepts,
generator design and performance as well as voltage regulation.
It is important to note that the information in this section applies, primarily,
to synchronous generators. The term synchronous describes the relationship
between the engine rpm and the generator output frequency; they are
exactly proportional.
SECTION CONTENTS
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Figure 2
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Generator Design
Generators are constructed in Amortisseur Windings
various ways to satisfy different Amortisseur windings, also known
load and customer requirements. as damper windings, are special
At Prime power ratings, SR4B conducting bars laid into a squirrel
generators are limited to 105C cage configuration. They are set in
(221F) temperature rise over an the notches in the rotor and then
assumed 40C (104F) ambient and are shorted on the end by either a
may be used on a continuous duty shorting ring or shorting laminations.
(24 hours per day) basis. They are used to increase machine
stability. This is due to the windings
SR5 generators are limited to a
and rotors relationship to the
125C (257F) temperature rise
synchronous speed. If the rotor is
over the same conditions.
at synchronous speed, there is no
At Standby power ratings, SR4B induced voltage through the
generators are limited to 130C amortisseur bars, hence there is no
(266F) temperature rise over an interaction. Conversely, if there is
assumed 40C (104F) ambient a differential between the rotor and
and are used many times for back-up synchronous speed, a voltage will
power needs, and are rated on a be induced in the windings. This
temporary use basis. voltage produces a current flow and
SR5 generators are limited to a in turn creates a magnetic field.
150C (302F) temperature rise The interaction of the two magnetic
over the same conditions. fields in turn cause a torque that will
The rating is expressed in kilowatts correct this speed difference
(kW) at 0.8 power factor. A resulting in speed and torque
common ratio, kW divided by stability.
0.8 permits calculation of kilovolt- Salient Pole Rotor
amperes (kVA) on all generators. A rotor configured with the
individual rotor poles protruding from
Rotor the center of the rotor is known as a
The rotor is defined as any rotating salient pole rotor.
winding or element of a generator.
It can be described as an assembly The rotating salient pole field
of thin magnetic steel laminations, arrangement is affected by
tightly compressed and then riveted, reluctance torque and is used for
bolted or welded together to form a engine-driven generators on most
magnetic path. It is around this core machines in the 20 kVA (16 kW)
that the field windings, or coils of and larger sizes.
conducting material, are wound Non-Salient Pole Rotor
around or inserted. A non-salient pole rotor, or
cylindrical rotor, is typically made
from solid cylindrical material and
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usually has grooves cut into the pole thick steel stampings/ laminations
faces to place the windings. stacked together. Stacking machines
A rotating non-salient pole field, use automatic welding to assure
or cylindrical rotor, isnt affected correct stator skew, stack pressure,
by reluctance torque and it is mainly and slot alignment. Stator stampings
used for large, steam turbine-driven are usually stamped from special
generators. The non-salient silicone steel.
configuration usually has grooves The stator core is subjected to
cut into the pole faces to place the an alternating magnetic flux which
windings. induces currents, called eddy
currents, in the core that create
Permanent Magnet Rotor
losses. Creating the core from
A permanent magnet (PM) field
stacked stampings rather than from
eliminates the need for an exciter
one solid piece of steel inhibits eddy
and therefore is very cost effective
currents, reducing losses. The
in smaller size generators. The
silicone added to the steel stampings
disadvantage to this is that its flux
and an oxide coating help to inhibit
density (field strength) is constant
eddy currents.
and voltage regulation is poor.
However, if it is to be used in an In addition to eddy current losses
application with a steady load and in the stator core, there are
minor fluctuations, a PM field can hysteresis losses. One definition of
be very effective. hysteresis is the failure of a property
that has been altered by an external
A rotating armature, stationary
agent to return to its original value
field generator is used mainly in
when the cause of the alteration is
small, low-voltage machines. A
removed. Figure 5 illustrates
common use for this generator is as
hysteresis.
an exciter for brushless generators.
For additional discussion of PM The B-H curve in Figure 5 shows
used in larger generator excitation that unmagnetized iron starts at zero
systems, refer to Exciter & Regulator and proceeds to saturation as the
Characteristics and Performance- magnetomotive force (MMF)
Permanent Magnet. increases. In simpler terms, the
unmagnetized iron becomes
Stator magnetized. As MMF is reduced to
The stator is defined as any zero again (or as the iron loses its
stationary winding or element of a magnetism), a residual B results.
generator. The stator core is where The residual B means that the iron
the usable electricity is generated. does not entirely lose its magnetism
The windings carrying the usable when MMF returns to zero. The
electricity are placed in the stator same curve loops around as MMF
core slots. becomes negative then positive
The stator core is made up of again from an AC exciting current.
hundreds of 0.0185 in. to 0.025 in. Since the hysteresis loop results in
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Stator Windings
Figure 8
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Random Winding
Figure 9
Coil Pitch
When a coil is wound 180
electrical degrees, the voltages on Figure 10
the conductors on either side are
equal in magnitude and opposite in Random wound coils are wound
direction and are said to be a full with round copper magnet wire that
pitch coil. Sometimes a coil is is insulated with a moisture resistant
wound less than 180 and is said to heavy polyester film and amide-imide
be a fractional pitch coil. The reason overcoat. Containing multiple
for this is to reduce certain harmonic conductors per turn, the coils
factors that will be discussed later consist of one or many turns each
in this guide. SR5 generators are and are wound in a double diamond
2/3-pitch. shape. Random wound coils are cost
Winding Types effective and are suited for low
Winding types can be random or power ratings, standby applications,
formed. Random windings utilize clean environments, and low
coils of round wire. Material costs operating hours.
are lower, but this method leaves
spaces between the individual wires.
Formed windings utilize square or
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Random Wound Stators that are treated However, the list is by no means
using the dip and bake process are initially
complete. In the US, system
submerged into a polyester
resin. Polyester resin is used for its superior voltages are based on 120V with
heat dissipation, flexibility, voltage breakdown multiples of that voltage.
strength, and moisture resistance. The resin
Nominal System Identical System
penetrates the spaces between the
conductors and leaves a uniform resin build. Voltages* Voltage
The resin is then cured by a bake cycle. By 120 110, 115, 125
holding the conductors together, the resin
120/240 110/220, 115/230
prevents vibration and premature failure. Once
the polyester resin is cured, the stator is 208Y/120 199Y/115
dipped and baked using an epoxy resin. The 240 220, 230
epoxy adds extra protection against moisture,
chemicals, and other environmental factors. If 400, 480 440, 460
requested and/or necessary, additional dips 600 550, 575
and bakes maximize resin buildup and
environmental protection. As many as 2 to 4 2400 2200, 2300, 2500
dips and bakes are possible. To further protect 4160Y/2400 3810, 4000
against abrasion and moisture, asphalt epoxy
is also applied to the lead end. Also, end Table 2
windings are sprayed with red sealer to help
retard voltage tracking and to seal all parts
from rust and corrosion. Tracking is caused by
Caterpillar system voltages
contaminants like salt water, which can get are divided into three classes to
trapped on the coil end turns. Surface currents differentiate between types of
then develop and carbonize or track the resin generators. The classes are Low
surface.
Random Wound and Form Wound stators Voltage, Medium Voltage and High
that are treated using the Vacuum Pressure Voltage.
Impregnated (VPI) process are placed in a
sealed tank in which all air is drawn out and
Low Voltage A class of
then filled with polyester or epoxy resin. This nominal system voltages of
process maximizes the ability for the resin to 1 KV or less
penetrate and adhere to the windings. To
further protect against abrasion and moisture, Medium Voltage A class
asphalt epoxy is also applied to the lead end. of nominal system voltages
Adding coastal insulation protection, an greater than 1 KV, but less
optional epoxy based coating, can further
strengthen the insulation coating. This optional
than 100 KV
coating is required to prevent premature High Voltage A class of
standard insulation deterioration in harsh nominal system voltages equal
environments that contain high levels of
abrasive (sand, salt or dust) or corrosive (salt to or greater than 100 KV and
or other chemicals) air borne contaminants. equal to or less than 230 KV
Note: The integrity of all types of generator Caterpillar may supply generators
winding insulation systems is distinctly
improved when moisture is restrained from
up to 15 KV in some applications.
collecting on winding insulation. During Applications above 15 KV are used
generator nonuse periods, it is highly for transmission voltages and are
recommended to use space heaters to prevent used in vary large power plant
moisture collection.
generators or they are specifically
Table 2 shows examples of system developed for step up transformers.
voltages that may be encountered.
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Table 3
Figure 13
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includes the hot spot. Note that an representative. Note that this type of
embedded detector can measure the graph is used to compare insulation
temperature limit of the stator systems. These curve bands do not
windings and is usually a standard predict actual design life of a
factory test. Because the rotor is machine. For example, one CANNOT
rotated, however, an embedded assume that the design life of a
detector cannot test the field machine is any given number of
windings; they must be tested by hours because the insulation life is
resistance. a given number of hours. The curve
There are two basic types of bands only COMPARE insulation
embedded detectors; Resistive systems.
Temperature Devices (RTD) and Note: For every 10C (18F)
thermocouples. increase in temperature, insulation
An RTD is an electronic sensing life is halved.
device that varies resistance with a
change in temperature. This change Sample Thermal Endurance
in resistance is then measured and Curve Band
converted into a temperature
reading. The RTD delivers more
of an average reading than the
thermocouple.
The thermocouple is another type
of temperature sensing device. It is
typically used in random wound
machines due to its sturdier design.
The thermocouple delivers a reading
at a precise point, usually the hot- Figure 14
spot. Both devices can be placed in
windings and the machines There are several indications that
bearings. They can show increases thermal deterioration is occurring in
in winding insulation temperature winding insulation.
and prevent excess bearing heat Loss in weight and thickness
effects. Increase in stiffness or
Thermal endurance is the ability brittleness
of the insulation to withstand heat. Increase in density
Figure 14 shows typical thermal
Non-uniform shrinkage with
endurance curve bands for the
cracks penetrating from the
different insulation classes. The
surface
curve bands predict insulation life in
hours versus the temperature of the Reduced tensile strength
windings. There are many test Less resistance to moisture
points outside these bands; the penetration
points shown are merely
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Open Delta
Figure 17
Figure 18 Figure 20
Several single-phase connections
are possible for 2-wire or 3-wire
Generator Features and
loads. These connections are Attachments
normally used only on smaller Several attachments and features
generators at or below 250 kW. can also be configured to assist
An open delta, as shown in in meeting generator requirements.
Figure 19 is reconfigured from an These include bearings,
original delta from three-phase to environmental protection devices
single-phase use; this type of and space heaters.
connection, however, will only Bearings
provide approximately 57% of the Bearings are devices that permit
original three smooth movement between
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Inertia
Water Ingress Protection Inertia data is essential to studies
(second digit of IP designation) of transient response, such as the
Second
Description effect of a larger generator with
Digit more rotor weight and greater mass
0 Non-Protected Machine moment of inertia. When the
Machine protected against
1 information is given to an engineer,
dripping water
Machine protected against
it must be correctly identified.
2 dripping water when machine These figures list the mass
is tilted up to 15 moment of inertia in System
Machine protected against
3 International (SI) units and English
spraying water
Machine protected against
units. Other symbols used to
4 designate inertia of rotating
splashing water
Machine protected against machinery are WK2, WR2, and GD2.
5
water jets The standard inertia presentation
Machine protected against below is globally recognized and can
6
heavy seas
be readily converted to other inertia
Machine protected against
7 designations.
effects of immersion
Table 5 Force x Distance x Time2
Nm sec2 = Newton x meter x Second2
Two types of IP protection are lbin. sec2 = lb x in. x Second2
totally enclosed water cooled
(TEWAC) and totally enclosed air To convert to moment of inertia
cooled (TEAC). (WK2) in SI units:
Multiply Nm sec2 by 9.803
Physical Data m/sec2.
Rotor Weight Multiply lbin. sec2 by 2.683 to get
Rotor weight indicates the total inertia (WK2) in lbft2, the common
weight of the generator rotor. When English unit designation.
used with the formula for inertia, the
Center of Gravity
flywheel effect of the generator can Center of gravity is information
be found. Engineers may use these that gives the location of the
figures when generator loads are generator center of weight in three
sudden or cyclic. planes. With the total generator
Stator Weight weight, the information can be used
Stator weight is given in kilograms to determine the center of gravity
and pounds and gives an indication of an assembly consisting of engine,
of the capacity of a generator. generator, radiator, and base.
Engineers generally assume that a Combined calculations require
heavier stator contains more reducing all values to moments
working copper and iron and (lbin. or kgmm). These are
therefore has greater capabilities. summed algebraically in each plane
of reference.
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Temperature Rise
Method of Temperature Rise, Degrees C
Item Machine Part Temperature Class of Insulation System
Determination A B F H
a. Armature Windings
1. All kVA ratings Resistance 60 80 105 125
2. 1563 kVA and Embedded
70 90 115 140
less detector**
3. Over 1563 kVA
a) 7000 volts and Embedded
65 85 110 135
less detector**
Embedded
b) Over 7000 volts 60 80 105 125
detector**
b. Field Winding Resistance 60 80 105 125
c. The temperature attained by cores, amortisseur windings, collector rings, and
miscellaneous parts (such as brushholders, brushes, pole tips, etc.) shall not
injure the insulation or the machine in any respect.
* For machines which operate under prevailing barometric pressure and which are designed not to exceed the specified
temperature rise at altitudes from 3300 feet (1000 meters) to 13000 feet (4000 meters), the temperature rises, as
checked by tests at low altitudes, shall be less than those listed in the foregoing table by 1 percent of the specified
temperature rise for each 330 feet (100 meters) of altitude in excess of 3300 feet (1000 meters).
** Embedded detectors are located within the slot of the machine and can be either resistance elements or
thermocouples. For machines equipped with embedded detectors, this method shall be used to demonstrate conformity with
the standard (see 20.63).
NOTES:
1Temperature rises in the above table are based upon generators rated on a continuous duty basis. Synchronous
generators may be rated on a stand-by duty basis (see 22.85). In such cases, it is recommended that temperature rises not
exceed those in the foregoing table by more than 25C under continuous operation at a stand-by rating.
2Diesel engine specifications often call for machines which are suitable for 10-percent overload for 2 hours out of any
24 consecutive hours of operation. Generators having a corresponding overload capability are sometimes required. In such
cases, it is recommended that the generators and their excitation systems be designed to deliver 110 percent of kVA at
rated power factor, frequency, and voltage with temperature rises under rated load conditions not exceeding those given in
the above table.
3Temperature rises in the foregoing table are based upon a reference ambient temperature of 40C. However, it is
recognized that synchronous generators may be required to operate at an ambient temperature higher than 40C. The
temperature rises of the generators given in the foregoing table shall be reduced by the number of degrees that the ambient
temperature exceeds 40C. (Exceptionfor totally enclosed water-air-cooled machines, the temperature of the cooling air
is the temperature of the air leaving the coolers. Totally enclosed water-air-cooled machines are normally designed for the
maximum cooling water temperature encountered at the location where each machine is to be installed. With a cooling
water temperature not exceeding that for which the machine is designed.
a. On machines designed for cooling water temperatures from 5C to 30C the temperature of the air leaving the
coolers shall not exceed 40C.
b. On machines designed for higher cooling water temperatures the temperature of the air leaving the coolers shall be
permitted to exceed 40C provided the temperature rises of the machine parts are then limited to values less than those
given in the table by the number of degrees that the temperature of the air leaving the coolers exceeds 40C.)
Table 6
Maximum Momentary Overloads overload with the field set for normal
Synchronous Generators shall be rated load excitation in accordance
capable of carrying a 1-minute with Table 7.
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Armature Current, % of
Synchronous Speed rpm
Normal Rated Current TIF According to the 1960 Single
1801 and Over 130 Frequency Weighting
1800 and Below 150 Frequency TIF Frequency TIF
Table 7 60 0.5 1860 7820
180 30 1980 8330
It is recognized that the voltage 300 225 2100 8830
and power factor will differ from the 360 400 2160 9080
420 650 2220 9330
rated load values when generators
540 1320 2340 9840
are subjected to this overload
660 2260 2460 10340
condition. Also, since the heating
720 2760 2580 10600
affect in machine winding varies 780 3360 2820 10210
approximately as the product of the 900 4350 2940 9820
square of the current and the time 1000 5000 3000 9670
for which this current is being 1020 5100 3180 8740
carried, the overload condition will 1080 5400 3300 8090
result in increased temperatures and 1140 5630 3540 6730
a reduction in insulation life. The 1260 6050 3660 6130
generator shall therefore not be 1380 6370 3900 4400
subjected to this extreme condition 1440 6650 4020 3700
for more than a few times in its life. 1500 6680 4260 2750
It is assumed that this excess 1620 6970 4380 2190
1740 7320 5000 840
capacity is required only to
1800 7570
coordinate the generator with the
control and protective devices. Table 8
Maximum Deviation Factor Shall not exceed the values in
The deviation factor of the open Table 7.
circuit line-to-line terminal voltage
kVA Rating of Generator TIF
of synchronous generators shall
125 to 4999 150
not exceed 0.1.
5000 to 19999 75
Telephone Influence Factor (TIF) 2000 and Above 70
Telephone Influence Factor (TIF) Table 9
shall be measured at the generator
terminals on open circuit at rated When specified, the residual
voltage and frequency. When component TIF based on the
specified, the balance TIF is based weighting factors given shall not
on the weighting factors in Table 8. exceed the values in Table 10.
These residual components apply to
those voltage ratings 2000 volts or
higher.
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Figure 21
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Assume each coil in Figure 24 and For resistance of 1-2, 2-3, 3-1
Figure 25 represents an equal (line-to-line), multiply the coil
resistance value in ohms. The resistance by 4.
numbers shown represent the line For resistance of 1-4, 2-5, 3-
and neutral in the stator windings. 6, 7-0, 8-0, 9-0 (individual
The figures show the points at coil resistance), single coil
which the listed resistance value resistance applies.
or a multiple of it applies.
For resistance of 1-0, 2-0,
In Figure 24, the generator coils and 3-0, multiply the coil
are connected in parallel for low resistance by 2.
voltage.
Resistance measurements will be
valid only if made with instruments
capable of measuring very low
resistance. Do not attempt to use
an Ohmmeter. The inaccuracy is
too great to have any value.
Resistance values vary with
temperature. Given resistance values
apply only at 25C (77F).
Correction must be applied at other
Figure 24
temperatures. For temperatures
For resistance of 1-2, 2-3, or other than 25C, multiply the listed
3-1 (line-to-line), single coil value by 0.00393 and then by the
resistance value applies. total temperature difference
between 25C and the existing
For resistance of 1-0, 2-0, or temperature. Add the result to the
3-0 (line-to-neutral), divide the listed value if the temperature is
coil resistance by 2. higher. Subtract the result if the
In Figure 25, the generator coils temperature is lower.
are connected in series for high A reverse process can find internal
voltage. temperature of generator coils. The
generator stator resistance must be
accurately measured.
Open Circuit Time Constant
The open circuit time constant is
determined from a test performed as
follows:
The generator is operating at
normal rated voltage with no
Figure 25 load.
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In time, within one to five cycles, are about one-half the transient
the asymmetrical current declines reactance per unit value.
to a very low value. From that time Some engineers also use sub-
forward, the symmetrical current is transient reactance to determine
the only significant current. the approximate voltage dip on
The maximum asymmetrical short a generator when starting large
circuit RMS current can be found by motors.
multiplying the RMS symmetrical
Synchronous Reactance (Xd)
value by square root of 3. In the After transient conditions have
above example, the generator will occurred, current flow is determined
produce 2190 x 3 = 3793 RMS by the synchronous reactance.
amperes, asymmetrical. This is a steady state value and
Calculations involving circuit is effective after approximately
breakers normally require peak five seconds.
currents. Symmetrical and
asymmetrical currents from a
Caterpillar generator can be
converted to peak values by
multiplying either value by the
square root of 2. In the above
example, the generator will
produce: 2190 x 2 = 3096
peak symmetrical amperes or
3793 x 2 = 5363 peak
asymmetrical amperes. Figure 29
Note that a smaller sub-transient
Synchronous reactance is
reactance per unit value results in
identified by the symbol Xd and
higher available short-circuit current.
has a per unit value of 2.0 to 4 in
Available short-circuit current is Caterpillar generators. This factor
sometimes expressed as a multiplier is used to determine the steady-
(called available current ratio), which state fault current capability of a
is the reciprocal of the per unit sub- separately excited generator. This is
transient reactance. For this the short circuit current which would
generator: be produced after five seconds. Self-
1 excited generators, such as the SR4,
= 8.326
0.1201 lose excitation before five seconds.
Therefore, the synchronous
Rated current times that multiplier reactance factor cannot be used to
equals RMS symmetrical current: determine the actual steady-state
fault current. The factor does,
263 Amperes x 8.326 = 2190 however, give a comparison with
Per unit sub-transient reactance other generators by considering the
values of Caterpillar generators
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Application and Installation Guide Generator Systems
2008 Caterpillar
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Generator Systems Application and Installation Guide
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Application and Installation Guide Generator Systems
2008 Caterpillar
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Generator Systems Application and Installation Guide
2008 Caterpillar
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Application and Installation Guide Generator Systems
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Generator Systems Application and Installation Guide
Miscellaneous Terms
Overspeed Capability may be necessary. Refer to the
Overspeed capability is the ability altitude/temperature de-rating chart
of the generator to handle the in TMI or consult your Caterpillar
sudden increase over rated rpm due dealer.
to the removal of a large load. This Where the temperature of the
is usually on the order of 125 to ventilating air to the generator
150% of rated rpm. exceeds 40C (104F), de-rating of
Heat Dissipation the generator may be necessary. See
Heat dissipation occurs when a Figure 33 for general capabilities.
device is heated due to current flow. Non-Linear & Unbalanced Loads
Some electrical energy is then lost Non-linear loads & unbalanced
from the energy used in the heating loads generate harmonic currents
of this device. that cause waveform distortion of
Derating the generator. In this situation,
Generator de-rating refers to the excess heat can be created and
need to lower a generators rated a larger generator may be needed.
operating capabilities due to an Crest Factor
environmental reason or a load Crest factor is the peak voltage
affect. This situation requires the divided by the RMS voltage.
use of a larger generator than
Distortion Factor
would be necessary under normal
Distortion factor is the sum of
conditions. Several examples of
the harmonics divided by the RMS
these conditions are as follows:
voltage.
Altitude
For application over 3300 ft
elevation, derating of the generator
Figure 33
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Application and Installation Guide Generator Systems
Generator Limits
Rating limits are occasionally thermal limits. Unfortunately, it is
illustrated as shown in Figure 34; typically not possible to monitor the
kVA and kW versus power factor. temperature directly because this is,
The fluctuations in the kVA line normally, a rotating device. In this
represent the generator operating right quadrant, the generator output
limits. It is important to note that is only limited by the generators
every generators limit tendency to become self-excited
characteristics are different and with a high leading power factor.
cannot be classified by size or type. While operating in the leading
For example, the limits for a standby power factor condition, there is
generator are less limiting than for a tendency for an overvoltage
an equivalent prime-continuous condition. An overvoltage condition
generator. In another example, field may affect the successful operation
heating limits may be the limiting of the automatic voltage regulator.
factor at 0.8 PF, or they may not If the generator operates in the
limit the generator at all. left quadrant of Figure 34, it has a
The engine is many times the lagging power factor. It is limited
limiting factor in a genset as shown here by both the rotor (field) and
by the engine kW limit line. stator (armature) heating. Many
If the generator operates in the times, the field temperature limit
leading power factor quadrant, it is lower than the armature limit,
operates on a capacitive load. In this especially at low power factor
condition, the rotor is subject to values.
heat generation and may reach
Figure 34
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Application and Installation Guide Generator Systems
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Application and Installation Guide Generator Systems
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Application and Installation Guide Generator Systems
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Application and Installation Guide Generator Systems
2008 Caterpillar
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LEBW4993-02 2008 Caterpillar Printed in U.S.A.
All rights reserved.