AN INTRODUCTION TO

What does BRUSHLESS Generator mean?

D.C. FIELD POLES

OUTPUT

CARBON BRUSHES

SHAFT

A.C.ARMATURE

SLIPRINGS BEARINGS

30 years ago, A.C Generators were designed with SLIPRINGS and CARBON BRUSHES, to transfer power from the rotating component of the Generator. These had a tendency to wear out, spark, burn, with vibration or high transient load currents. BRUSHLESS Generators are designed to allow output to be taken from the Generator WITHOUT SLIP-RINGS AND BRUSHES.

NOW LETS LOOK AT A BRUSHLESS GENERATOR !!

Two Bearing Main Rotor Assembly

Exciter Rotor Bearing Main Rotor Fan

Bearing

Shaft

PMG Rotor
Rectifier

Bearing

Housings are built into the D.E and NDE Endbrackets Bearings are sealed for life.

Air flow through Generator Air flow must not be restricted

Excitation System - All Generator types

Main Stator Exciter Rotor & Stator Bearing

Main Rotor

Shaft

Rectifier Fan

Excitation System - Exciter Stator

Exciter Stator
Exciter Rotor & Stator Bearing

Main Stator

Main Rotor

Shaft

Rectifier Fan

Excitation System - Wound Exciter Stator

X+ (F1) XX- (F2)

To A.V.R Terminals

COIL CONNECTIONS

High-remanence steel core Stores Residual Magnetism 12-14 pole magnet field High frequency Generator

Excitation System - Exciter Rotor

Exciter Rotor
Main Stator Exciter Rotor & Stator Bearing

Main Rotor

Shaft

Rectifier

Fan

Excitation system - Exciter Rotor Assembly

W U

SHAFT

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.

Excitation System - Exciter Rotor/ Main Rectifier

Exciter Rotor and Main Rectifier Circuit
Main Stator Exciter Rotor & Stator Bearing

Main Rotor

Shaft

Rectifier

Fan

Exciter Rotor and Rectifier Assembly

Wound Exciter Rotor
W U

Rectifier Assembly
V

SHAFT SHAFT

U
W Rectifier Assembly Mounted on Exciter rotor Core, (drive end side).

Exciter Rotor & Main Rectifier Assembly

Exciter Rotor 3 Phase with Internal Star Point

SHAFT

Exciter Rotor & Main Rectifier Connections

Rectifier Input Terminal

SHAFT SHAFT

3 Phase A.C Exciter Rotor Connected to Rectifier input terminals

Excitation System - The Main Rectifier

Main Rectifier
Main Stator Exciter Rotor & Stator Bearing

Main Rotor

Shaft

Rectifier

Fan

Main Rectifier Assembly

3 Phase A.C Input from Exciter Rotor. (Insulated Terminals) Split Two-Piece Rectifier Hub Rectifier Diodes Positive Plate Cathode Stud Aluminium Heat-sinks Varistor (Surge Suppressor)

SHAFT

Rectifier Diodes Negative Plate Anode Stud

Main Rectifier Assembly- Operation of a Diode

A.C Input to Rectifier Diodes ( 150 HZ to 180 HZ per second) Rectifier Diode Positive Heatsink Cathode Stud

+VE
0 -VE +VE 0 -VE

+
Rectifier Diode Negative Heatsink Anode Stud

+VE 0 -VE

Main Rectifier Assembly- 3 Phase Rectification

A.C Input to Rectifier Diodes (150 to 180HZ)

D.C output to Main Rotor

Full wave 3 Phase rectification will produce a D.C output of 1.35 X A.C input voltage

Metal Oxide Varistor (Surge Suppressor)

Clamping @ 30 Amp 680 Volts Clamping @ 100 Amp 1365 Volts

Diode Protection Device For Transient Suppression

SHAFT

Main Rotor Connections

SHAFT

Metal Oxide Varistor (Surge Suppressor)

DIODE PROTECTION DEVICE

Direction of transient

Typical high voltage transient created by fault condition in the distribution system. Up to 2- 3000V (peak voltage)

Energy absorbed
by Varistor.

Varistor clamping
(Protection) level.

High Transient surges can be created by: Crash Synchronising onto live bus-bars. Electric storm, (lightning), and field effects on overhead lines (distribution systems). Arcing, caused by faulty switching, motor failure, short circuits in the distribution system.

Full load D.C output from main Rectifier

t = sec's.

D.C supply to Main rotor

Excitation System - The Main Rotor Main Rotor

Main Stator Exciter Rotor & Stator Bearing

Main Rotor

Shaft

Rectifier
Fan

Main Rectifier Connections to Main Rotor

Main Rectifier
Aluminium Heat-sinks

Main Rotor

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

Wound Main Rotor - Coil Group connections

ANTI CLOCK

D.C Input From Main Rectifier

CLOCK

S
N S
ANTI CLOCK

CLOCK

The Rotor coils are connected in Series (4 Pole Rotor shown). Each coil is reversed to the adjacent coil, producing the required polarity

Wound Main Rotor - Poles & Frequency

Main Stator Coils in Slots (section) 4 Pole Main Rotor Air Gap 1 Cycle Main Stator Core (section)

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

Wound Main Rotor - Poles & Frequency

Main Stator Coils in Slots 4 Pole Main Rotor Air Gap 1 Cycle Main Stator Core

The Rotor has now rotated Clockwise 45 , 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.

Wound Main Rotor - Poles & Frequency

Main Stator Coils in Slots 4 Pole Main Rotor Main Stator Core

Air Gap
1 Cycle

N
S
SHAFT

The Rotor has now rotated Clockwise 90 , 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 FULL REVOLUTION.

Wound Main Rotor - Poles & Frequency

Generator Frequency (HZ) = Speed (N) X Pairs of poles (P) 60

4 Pole

6 Pole Available in Frame 7

2 Pole

S N
SHAFT

N N
SHAFT

Wound Main Rotor - Poles & Frequency

Generator Frequency (HZ or CYCLES) = Speed (N) X Pairs of poles (P) 60
FRQUENCY HZ (CYCLES) 50 50 50 60 60 60 NUMBER POLES (P) 2 4 6 2 4 6 ENGINE SPEED (N) 3000 1500 1000 3600 1800 1200

2 Pole 1 HZ = 60 RPM 4 Pole 1 HZ = 30 RPM 6 Pole 1 HZ = 20 RPM

Main Rotor- Amortisseur (Damper) Windings

S N
SHAFT

(Damper Bars) (Aluminium Damper Bars Welded to End Plates )

Main Rotor- Amortisseur (Damper) Windings

S N
SHAFT

Helps dampen speed oscillations resulting from cyclic irregularities in the engine, (cause of light flicker). Stabilises the mechanical systems during large load changes. Stabilises load sharing with other Generators in Parallel. Improves Harmonic Distortion in the Generator waveform

Operation - Main Stator

Main Stator
Main Stator Exciter Rotor & Stator Bearing

Main Rotor

Shaft

Rectifier Fan

Wound Main Stator Assembly

Core built from high grade Electrical Steel, to reduce Iron losses (heat). Each lamination is electrically insulated to minimise Eddy Currents in the core. 12 Ends Out Re-connectable, 6 Ends out Star / Delta, or Dedicated Windings. Class H Insulation as standard, 125 C Temperature rise in 40 Ambient. 2/3rds Pitch windings, Harmonics virtually eliminated.

Laminated Steel core Output Leads

Copper Windings

Wound Main Stator Assembly

Stator Winding Coils (Lap winding)
COIL PHASE GROUP OUTPUT CONDUCTORS OUTPUT CONDUCTORS COIL END (OVERHANG)

STATOR CORE LENGTH

COIL SPAN (PITCH)

COIL TURNS

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.

Typical Main Stator 12 Wire Re-connectable

WINDING LEADS START OF COIL GROUP WINDING LEADS FINISH OF COIL GROUP 2/3RDS PITCH 8 SLOTS ( SPAN 1 TO 9) ONE PHASE GROUP ( 4 COILS PER GROUP) FULL PITCH 12 SLOTS ( SPAN 1 - 13)

S N
SHAFT

MAIN ROTOR (4 POLE)

MAIN STATOR WINDING SECTION ( 48 SLOT )

Typical Main Stator 12 Wire Re-connectable

Connections shown in Series Star

N
6

V6

Neutral

W V U

W1 3 Phase Output V1

AVR Sensing & Power supply 7 from Main Stator

8

U1

Wound Main Stator 12 Wire Re-connectable

Series Star
Voltage Range 380 to 440 V @ 50 HZ 416 to 480 V @ 60 HZ U1 U1 U2 U5

Parallel Star
U
8
U5 Voltage Range 190 to 220 V @ 50 HZ 208 to 240 V @ 60 HZ

8
U2 U6

W6

U6 V6

N
W2 V2 W1

6
W2 W1

V6
V5

W5

V5

V1

W6 V2
W5 V1

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.

Wound Main Stator 12 Wire Re-connectable

Series Delta
Centre Tap

Double Delta
6

Voltage Range 220 to 250 V @ 50 HZ, 240 to 277 V @ 60 HZ No Neutral connection. Centre Tap for low volts 1ph only

Voltage Range 220 to 250 V @ 50 HZ, 240 to 277 V @ 60 HZ Single Phase Only, output across U & W Centre Tap (N) for low volts 110 to 125 @ 50 HZ, 120 to 138 @ 60 HZ

Wound Main Stator 6 Ends Out

Star
U
Voltage Range 380 to 440 V @ 50 HZ, 416 to 480 V @ 60 HZ Single Phase (N) = 3 of Phase voltage Dropper transformer required for AVR sensing 8
U1

U2

Number of Stator leads in parallel increases with current rating of generator, ie: 12, 18, 24, 36, or 48 leads out.

N
W2
V2

6 W1

V1

Each phase group is producing the full line voltage, (all coil groups in each phase are in parallel).

Wound Main Stator 6 Ends Out

Sensing Supply to A.V.R for STAR connection U
Examples - 6 ends Stators 380 to 440 V @ 50 HZ 416 to 480 V @ 60 HZ Single Phase (N) = 3 of L-L U1

U2

Isolation transformer
N 8
V2

W2

W1

V1

w
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

Main Stator Windings -Voltage Ranges

The output voltage of the generator is set by adjustment of the AVR Voltage trimmer. The potential voltage range of the AVR can be much higher or lower than the design limits for the Generator windings. The Voltage Range is decided by many inter-dependant design considerations.

Main Stator Windings -Voltage Ranges

OPEN CIRCUIT MAGNETISING CURVE Each Winding is designed to operate within a specified Voltage Range. The Generator must operate within the Optimum Voltage Range for the Windings. Generator Output Voltage Maximum flux level Middle flux level Minimum Flux Level Output Voltage From Generator Open Circuit Magnetisation Curve Saturation

0 D.C Excitation Current

Excitation System - Self Excited Generators

X+ (F1) D.C Output From A.V.R Into Exciter Stator XX- (F2) A.C Power & Feedback Signal (Sensing) From Main Stator

A.V.R
Main Stator

Exciter Rotor & Stator Bearing

Main Rotor

Shaft

Rectifier
Fan

Excitation System - Self Excited Generators

AVR Input Power & Sensing 170 - 250 Volts A.C. 2 or 3 Phase sensing

AVR Output D.C

A.V.R Automatic Voltage Regulator X+ D.C XXMain Rectifier

To Load Terminals Generator Output A.C. 50 or 60 HZ

Exciter Stator ( Residual Magnetism)

Main Stator 1 or 3 ph. A.C.

Magnetic Flux

Exciter Rotor

3ph A.C

A.C to D.C

Main Rotor D.C.

Shaft

Separately Excited Generators

ADVANTAGES OF SEPARATE EXCITATION SYSTEM
SUSTAINED SHORT CIRCUIT CURRENT UNDER FAULT CONDITIONS,

(REQUIREMENT FOR ALL MARINE CLASSIFICATIONS).

UNAFFECTED BY ADVERSE LOADING CONDITIONS SUCH AS

WAVEFORM DISTORTION CAUSED BY NON LINEAR LOADS

POWERFUL VOLTAGE BUILD UP SYSTEM ON INITIAL RUN-UP (DOES NOT RELY UPON RESIDUAL MAGNETISM) CAPABLE OF VOLTAGE BUILD UP AGAINST LOAD (FREQUENCY STARTING OF LARGE MOTORS). ISOLATED POWER SUPPLY FOR THE AVR. (PROTECTS AVR FROM TRANSIENT CONDITIONS IN THE DISTRIBUTION SYSTEM)

THANK U

Manufacturing Engineering Department (MED)