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ELECTRON NUCLEUS
(NEGATIVE CHARGE) (POSITIVE CHARGE)
VALENCE OR
ELECTROMAGNETIC CONDUCTIVE BAND
FORCE
2
ELECTRON ‘SHELL’
8
18
1
The ELECTRO MAGNETIC FORCE is second only in strength to the NUCLEAR
FORCE.
In a COPPER CONDUCTOR, the ELECTRON in the VALENCE band is FREE to flow
from atom to atom, when attracted by a POTENTIAL DIFFERENCE or CHARGE.
A COPPER CONDUCTOR
+ ELECTRON
ATOMS
20
= 10 per cubic mm FLOW IN A
(100 BILLION BILLION) CONDUCTOR
CURRENT flow is possible because of ‘free’ electrons in the atoms from which the
conductor is made.
IRON
CORE
Conductors are materials where the atoms have free electrons which can flow from
atom to atom, when induced by an electric charge (voltage).
Most metals are good conductors, some of the best being silver, copper and gold.
Good conductors have a very low resistance to current flow.
Copper conductors are generally chosen for Generator windings because of its
good electrical and thermal conductivity, relatively low cost, ease of use.
INSULATION IN INSULATION
A DOMESTIC IN A
CABLE GENERATOR
WINDING
IRON
CORE
Insulators are materials where, the electrons are very tightly bound to the nucleus
and to other atoms, (covalent bonding), hence there are no free electrons to carry an
electrical charge.
As a result, they are are a very poor conductors of electricity.
Typically rubber,plastics, ceramics and glass are good insulators. They have a very
HIGH resistance to current (electron) flow.
The Voltage level, temperature rise, electrical, and mechanical properties, all
determine the type of insulation materials chosen for a Generator winding.
+ -
12V D.C
BATTERY
The first battery was invented by VOLTA in 1800, and was called the
VOLTAIC PILE.
COPPER
& ZINC
CELLS
IN HE FOUND
SALT IT QUITE
WATER SHOCKING!
SOLUTION
In 1800,Volta invented the “VOLTAIC PILE”, which was the first BATTERY, and the
first Electrical device to produce a continuous ELECTRICAL CHARGE.
The VOLTAIC PILE was the fore- runner of the modern battery, with all its many
varieties today.
Electron flow
Copper
Conductor
Light
Switch Bulb
+ + -
D.C
BATTERY
0v
V
Anode
Gate
Silicon Controlled
Rectifier Diode
Rectifyer (Thyristor)
Cathode
The Engine or Turbine may be powered by various forms of potential energy i.e. :-
Fossil fuels, (Petrol, Diesel, or Gas), or fuels from waste products (Methane).
Steam from the heat produced by burning fossil fuels, or nuclear energy .
Water Turbines, (Hydro Electricity), driven by the pressure of water from a river
or Dam.
Alternative energy produced by wind or wave turbines.
PRIME MOVER
(ENGINE OR TURBINE) A.C GENERATOR
AP
PA
R EN
T PO
REACTIV WE
R(
E (kVAr) kV
N S A)
LAGGING
C OS
INDUCTIVE CAPACITIVE 90º
CIRCUIT CIRCUIT ACTIVE POWER ( kW )
Generator output RATINGS usually give the full load kWATTS and kVA at 0.8 P.F.
ZANUSSI
CORRECT !!
FRIDGE MAGNETS.
MAGNET
MAGNETIC
N S FLUX
Magnetism is the essential force which produces the ELECTRO MOTIVE FORCE
(EMF), in a Generator.
Without MAGNETISM, you would have no fridge to stick your fridge magnets to !!
CONVENTIONAL
- + CURRENT FLOW
(AMPERES)
D.C COPPER COIL
BATTERY (MAGNETIC FIELD)
MAGNETIC
N S
FLUX
When a D.C supply is connected to a copper coil, current will flow in one
direction through the coil, creating a magnetic field.
If an iron core is placed into the magnetic field, it will become magnetized. The
magnetic strength is determined by the D.C power (Voltage X Current) in the coil.
This is the principle of ELECTRO-MAGNETISM, which is used to control the
magnetic fields in an A.C Generators.
In 1831, Michael Faraday, using a simple magnet and a coil of wire,discovered that
mechanical energy could be converted into electrical energy,
MAGNET
COPPER COIL
(CONDUCTOR)
N S
When the magnet is stationary, no work is being done, so no electricity is generated.
When the magnet is moved rapidly passed the coil, work (energy) is being done, and
this will generate the ELECTRO MOTIVE FORCE, (EMF or VOLTAGE), into the coil.
-VE
A.C Sinusoidal Output Voltage with A Permanent Magnet Field
Electro- Magnetic
Magnetic Field Field
(Flux)
ADJUSTABLE
D.C SUPPLY
Shaft
Copper Slip-rings
loop and Brushes
+VE Output
-VE
By controlling the D.C current into the magnetic field, the voltage level can be
adjusted, allowing control of the output voltage.
CARBON
BRUSHES
SHAFT
SLIPRINGS
A.C
ARMATURE
WINDINGS ADJUSTABLE
D.C SUPPLY
The output Voltage is a product of (A), the strength of the magnetic field, (B),
the length of conductors in the A.C armature (turns), and (C), the velocity
(speed) of the conductors cutting the magnetic lines of force.
Primary Secondary
Winding Winding
(Input) (Output)
CB SUPER HIGH
TENSION
400,000V
MCB
STEP DOWN
TRANSFORMER
MCB
SHAFT A.C.ARMATURE
SLIPRINGS
BEARINGS
D.C INPUT
Before the Late 1960’s, Newage A.C Generators were designed with a rotating A.C
armature, from which the Generator output was taken.
This was achieved by means SLIP-RINGS and carbon ‘ BRUSHES’
These had a tendency to wear out, spark, burn, and required regular maintenance.
Newage switched to Brushless Generator design in the Late 1960’s.
This became feasible following the invention of the Silicon Diode Rectifier
SLIPRINGS
BEARINGS
This generator has a rotating field (rotor), which is supplied with D.C via two slip-rings.
The output is taken from the static A.C windings ( Stator),
This design is still popular today, as the rotating field system is easier to design than
a rotating armature, and more economical to manufacture.
The main components of a Brushless Generator are of a similar design to above.
However, Brushless Generators are designed without slip-rings and brushes.
NOW LETS LOOK AT A BRUSHLESS GENERATOR
BEARINGS
Bearing Bearing
Cartridge Cartridge
N.D.E D.E
Key
Shaft
P.M.G
Rotor
Rectifier
P.M.G
Stator
Bearing
Cartridge
N.D.E
P.M.G
Rotor
Rectifier
P.M.G
Stator
P.M.G
Rotor
P.M.G
Stator
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
Exciter
Stator
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
X+ (F1)
COIL CONNECTIONS
N S N S
Exciter
Rotor
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
W
U
SHAFT V
W
3 Phase A.C output, each Phase connected to 2 diodes on Main Rectifier.
High Frequency output, ( from12 to 14 Pole Exciter Stator ).
Exciter generator is a magnetic power amplifier for the main rotor current.
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
Rectifier Assembly
SHAFT
SHAFT V
W
Rectifier Assembly Mounted on Exciter rotor Core, (drive end side).
NOTE: BC & Frame 8 Generators are mounted at the non-drive end side.
SHAFT
SHAFT
SHAFT
Main
Rectifier
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
Rectifier Diodes
Negative Plate
Anode Stud SHAFT
Rectifier Diodes
Positive Plate
Cathode Stud
Output to
Main Rotor
+ 0
-VE
Rectifier Diode
Negative Heatsink +VE
Anode Stud
0
-VE
-
Full wave 3 Phase rectification will produce a D.C output of 1.35 X A.C input
voltage
SHAFT SHAFT
Main Rotor
Connections
Main Rotor
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
SHAFT D.C
The Rectifier Output is a smooth D.C Supply across the Aluminium Heat Sinks
This is fed to the Main Rotor windings
ANTI CLOCK
D.C Input
From Main S
Rectifier
CLOCK CLOCK
N N
ANTI CLOCK
S
N
SHAFT
N
N
SHAFT
S
S
Air Gap
1 Cycle S
N
SHAFT
Consider the Coils in the slot at 12 O'clock position, marked with the ARROW.
The NEGATIVE Pole of the 4 pole Rotor is directly under the slot, therefore the
coil conductors in this slot will be going fully NEGATIVE
Air Gap
1 Cycle
N
S
S
H
A
FT
N
S
The Rotor has now rotated Clockwise 45 º, until exactly half-way between
Negative and Positive Poles appears beneath the 12 O'clock position.
Air Gap
1 Cycle N
S
SHAFT
The Rotor has now rotated Clockwise 90 º, until the POSITIVE Pole is DIRECTLY
UNDERNEATH the 12 O'clock position.
The coil conductors in this slot will now be at the FULLY POSITIVE position
The 4 Poles will produce 2 FULL CYCLES for each 360 º FULL REVOLUTION.
50 2 3000
2 Pole 1 HZ = 60 RPM
50 4 1500 4 Pole 1 HZ = 30 RPM
6 Pole 1 HZ = 20 RPM
50 6 1000
60 2 3600
60 4 1800
60 6 1200
N
N
SHAFT
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
Core length of Stator & Rotor (L) Determines KVA Rating for each Frame size,e.g.
HC4 C, D ,E, F Core Lengths = 250 KVA to 400 KVA (@ 50 HZ)
HC5 C, D, E, F Core Lengths = 450 KVA to 675 KVA (@ 50 HZ)
HC6 G, H, J, K Core Lengths = 800 KVA to 1110 KVA (@ 50 HZ)
HC7 E, F, G, H Core Lengths = 1350 KVA to 2000 KVA (@ 50 HZ)
Core lengths
COIL END
(OVERHANG)
COIL
STATOR SPAN COIL
CORE (PITCH) TURNS
LENGTH
The output voltage of the stator is determined by the number of turns per coil, the
stator core length, the velocity of the magnetic field (rotor), and the strength of the
magnetic field.
The Current capacity of the coil is determined by the conductor cross sectional
area, and number of conductors in parallel.
GROUP 1
2/3RDS PITCH
WINDING LEADS V6 V2
8 SLOTS
START OF COIL U5 W1
( SPAN 1 TO 9)
GROUP U1
W5 ONE PHASE GROUP
WINDING LEADS W2
( 4 COILS PER GROUP)
FINISH OF COIL U6
GROUP
W6 FULL PITCH
12 SLOTS
S U2
( SPAN 1 - 13)
V5
GROUP 3 UP 4
V1 GRO
N
SHAFT
V1
V5
U2 S
W6
U6 W2
W5
U1
W1 U5 MAIN STATOR WINDING
V2 V6
MAIN ROTOR SECTION ( 48 SLOT )
GRO UP 2
(4 POLE)
6
WV6
N U6 Neutral
6 W5
W1
W2 W
AVR Sensing 3 Phase Output
& Power supply 7 V5
from Main Stator V2
V V1
U5
8
U2
U U1
U2 U5
8
U2 U6
W6 U6 N
W2 N V6
6 V6
V2
W2 V5
W1
W5 V5
W1 7 V1 6 W6 V2
w v w W5 V1 v
7
The stator windings are connected into six groups.
The groups can be connected by Newage, or the customer, to provide different voltage
requirements.
Special Voltage requirements require special windings, e.g.; 690 Volt for Co-Generation.
V6 V5 V2 V1 U1 U2 U5 U6
w v U N w
Star
U
8
Voltage Range (winding 312) Number of Stator leads in parallel
380 to 440 V @ 50 HZ, 416 to 480 V @ 60 HZ U1 multiply’s with current rating
Single Phase (N) = 3 of Phase voltage of generator,
Dropper transformer required ie: 12, 18, 24, 36, or 48 leads out.
for AVR sensing U2
N
W2 V2
7
6 W1 V1
w v
Each phase group is producing the full line voltage, (all coil groups in each phase are in
parallel).
7
W1 V1 7
w v
6 6
The AVR Sensing supply is connected to the main stator via a sensing
isolation transformer, which is fitted in the main terminal box.
Other windings producing higher voltage requirements will require a different
transformer ratio, to supply the AVR with the correct voltage adjustment range
The A.V.R
A.V.R
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
X+ (F1)
D.C Output A.C Power &
XX- (F2) A.V.R
From A.V.R Feedback Signal
Into (Sensing)
Exciter Stator From Main Stator
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
VOLTS X XX 6 7 8
1
2
3
4 WARNING!
ELECTRIC SHOCK
[Live Terminals]
UFRO
50HZ
C
60HZ
STABILITY
K2 K1 P2 P3 P4 XX X 3 2 2 1
S2 S1 A2 A1
TRIM
Input Var/ PFC3
[Live Terminals]
ELECTRIC SHOCK
WARNING!
DROOP Input Droop C/T
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
VOLTS
Linking for
3 Phase
Sensing Unit
UFRO STABILITY C B A
50 C 60
K2 K1 P2 P3 P4 XX X 3 2 2 1
S2 S1 A2 A1
TRIM
MX341-2 E000-23412
[Live Terminals]
ELECTRIC SHOCK
WARNING!
DROOP
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
VOLTS Linking for
3 Phase
Sensing Unit
EXC
DIP TRIP
UFRO STABILITY
3 2 C B A
1
RAMP
FREQUECY I /LIMIT
SELECTION
UFRO
3 2 1
ELECTRIC SHOCK
[Live Te rminals]
WARNING!
DIP
R.M.S
DWELL
STABILITY
STABILITY
SELECTION
E0 E1 B0 B1 C B A
Gate
A DIODE will conduct continuously, producing half wave rectification of the A.C supply.
A DIODE, however, would not CONTROL the D.C into the exciter field, which is necessary
to control the Generator voltage.
A SILICON CONTROLLED RECTIFIER (SCR or THYRISTOR) is a diode with a control
GATE.
The SCR will only switch ON when the GATE receives a signal from the AVR controls.
Bearing
Main Rotor
Shaft
Rectifier
Fan
The AVR switches the D.C power supply ON and OFF 50 - 60 times per second.
For PMG powered AVR,s 100 - 120 times per second.
Power ON
After time (T)
Number of pulses are the same as the A.C power
OFF OFF
supply frequency (50 or 60/second)
Power ON
After time
(T)
OF OF
F F
FULL LOAD D.C Pulses into the Exciter Stator X+(F1) XX-(F2)
(T)
The larger the pulse area (in RED) the higher the D.C power into the exciter stator..
. The AVR will stabilise at the new output level , when the sensing signal into the
AVR has returned to normal (nominal) voltage, as pre-set on the ‘VOLTS’ adjustment.
OFF OFF
Although the red pulses are now termed ‘OVERLOAD’, the AVR requires this
additional power to provide a rapid response to transient load application, ( to
reduce voltage DIP).
This short term response demands ALL of the power supply available for
approximately 0.3 seconds, until the output voltage has returned to normal.
P.M.G
Rotor
P.M.G
Stator
in Housing
PMG
Power
P2 -P3 -P4 X+ (F1) A.V.R A.C Feedback
Supply 6-7-8 Signal only.
To A.V.R
XX- (F2) (Sensing)
Main Stator from Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan