Transcript NEWAGE PRODUCT TRAINING

NEWAGE PRODUCT TRAINING
NEWAGE PRODUCT TRAINING
WHAT IS ELECTRICITY ?
 Electricity is a NATURAL form of ENERGY, e.g, LIGHTENING,
STATIC CHARGE.
 ALL forms of MATTER in the Universe, (solid, liquid or gas), are
made of ATOMS. The electrical force in the atom is called the
ELECTRO-MAGNETIC FORCE. This force holds ELECTRONS in
orbit, around the NUCLEUS of the ATOM.
 An electrical CHARGE, (or POTENTIAL DIFFERENCE),measured
in VOLTS), is created when ELECTRONS are stripped from ATOMS.
 This CHARGE, (or VOLTAGE), provides the ‘pressure’ in an
electrical circuit, causing ELECTRONS to flow in conductors.
Lets take a closer look at the ATOM
NEWAGE PRODUCT TRAINING
WHAT IS ELECTRICITY ? - THE ATOM
AA
HYDROGEN
COPPER ATOM
ATOM
NUCLEUS
(POSITIVE CHARGE)
ELECTRON
(NEGATIVE CHARGE)
VALENCE OR
CONDUCTIVE BAND
ELECTROMAGNETIC
FORCE
ELECTRON ‘SHELL’
2
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.
NEWAGE PRODUCT TRAINING
WHAT IS ELECTRICITY? - VOLTAGE AND CURRENT
A COPPER CONDUCTOR
ATOMS
20
= 10 per cubic mm
(100 BILLION BILLION)
+
ELECTRON
FLOW IN A
CONDUCTOR
 A POTENTIAL DIFFERENCE or CHARGE ,across a conductor, causes ELECTRONS to
flow towards the positive charge, (electrons are negatively charged).
The level of CHARGE is measured as VOLTAGE .
 CURRENT flow is possible because of ‘free’ electrons in the atoms from which the
conductor is made.
 CURRENT flow can also be described in terms of electron flow.
 1 Ampere flowing in a conductor at a given point in time would be equal to : 6 X 1018 electrons flowing / per second.
NEWAGE PRODUCT TRAINING
WHAT ARE CONDUCTORS
CONDUCTORS IN
A DOMESTIC
CABLE
CONDUCTORS
IN A
GENERATOR
WINDING
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.
NEWAGE PRODUCT TRAINING
WHAT ARE INSULATORS
INSULATION IN
A DOMESTIC
CABLE
INSULATION
IN A
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.
NEWAGE PRODUCT TRAINING
WHAT IS D.C (DIRECT CURRENT)
-
+
12V D.C
BATTERY
 Direct Current (DC) Voltage, can be produced by converting chemical
energy directly into electrical energy. This is the BATTERY.
 A BATTERY is a storage device, i.e., the battery stores potential energy,
which is known as the ‘charge’.
 The first battery was invented by VOLTA in 1800, and was called the
VOLTAIC PILE.
NEWAGE PRODUCT TRAINING
COUNT ALESSANDRO GIUSEPPE ANTONIA VOLTA 1745 - 1827
VOLTAIC PILE
COPPER
& ZINC
CELLS
IN
SALT
WATER
SOLUTION
HE FOUND
IT QUITE
SHOCKING!
 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.
NEWAGE PRODUCT TRAINING
A SIMPLE D.C CIRCUIT
Electron flow
Copper
Conductor
Switch
+
Light
Bulb
-
+
D.C
BATTERY
 The battery creates a POTENTIAL DIFFERENCE or CHARGE across its terminals.
 We measure this charge as VOLTAGE.
 The battery acts like a ‘pump’, forcing electrons to flow around the circuit.
 When the switch is closed, the potential difference causes free electrons to flow
through the conductors, and the light filament.
 The thin tungsten filament in the bulb acts as a ‘restriction’, or ‘resistance’, to the
electron flow, heating the element and producing light.
NEWAGE PRODUCT TRAINING
WHY IS D.C USED IN AN A.C GENERATOR?
A.C GENERATOR SET
ALTERNATING
D.C CONVERTED
CURRENT
FROM A.C
A.C
+V
0v
V
Anode
Gate
 Silicon Controlled
Rectifyer (Thyristor)
 Rectifier Diode
Cathode
 All Generators produce Alternating Current (A.C).
 A D.C Generator is an A.C Generator, with its output converted into D.C by means
of commutation, (reversal of the Negative cycle).
 In A.C Generators, D.C is produced by means of RECTIFICATION.
 D.C is used to produce the ELECTRO MAGNETIC FIELDS in A.C Generators.
NEWAGE PRODUCT TRAINING
WHAT IS A.C ( ALTERNATING CURRENT ) ?
 A.C Electricity (Alternating Current ), is produced by converting mechanical
energy into electrical energy. This is the A.C Generator.
 The mechanical energy is provided by an Engine, or Turbine which drives the
Generator.
 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.
NEWAGE PRODUCT TRAINING
THE A.C GENERATOR
PRIME MOVER
(ENGINE OR TURBINE)
A.C GENERATOR
 Mechanical power (HORSEPOWER) is converted into electrical power (KILOWATTS,
or kW) by means of a prime mover (engine) driving the A.C Generator.
NEWAGE PRODUCT TRAINING
WHAT IS A.C POWER ?
N
REACTIV
E (kVAr)
S
INDUCTIVE
CIRCUIT
LAGGING
90º
CAPACITIVE
CIRCUIT
ACTIVE POWER ( kW )
 ELECTRICAL POWER, (WATTS) in its simplest form = VOLTAGE X CURRENT
 A.C creates WASTED CURRENT in INDUCTIVE or CAPACITIVE circuits.
 The resultant APPARENT POWER , is called the kVA
 The POWER FACTOR, (COSINE of the phase angle  ), is a measure of the WASTED or
WATTLESS CURRENT component of the load.
 Generator output RATINGS usually give the full load kWATTS and kVA at 0.8 P.F.
SO, HOW DOES AN A.C GENERATOR PRODUCE A.C POWER ?
NEWAGE PRODUCT TRAINING
CAN ANYONE GUESS WHAT THIS IS ?
CAN ANYONE GUESS WHAT THESE ARE ?
ZANUSSI
CORRECT !!
FRIDGE MAGNETS.
BUT WHAT’S THAT GOT TO
DO WITH A.C GENERATORS ?
NEWAGE PRODUCT TRAINING
MAGNETISM IN GENERATORS
MAGNET
N
S
MAGNETIC
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 !!
NEWAGE PRODUCT TRAINING
ELECTRO- MAGNETISM IN GENERATORS
-
+
COPPER COIL
(MAGNETIC FIELD)
D.C
BATTERY
N
CONVENTIONAL
CURRENT FLOW
(AMPERES)
S
MAGNETIC
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.
NEWAGE PRODUCT TRAINING
MICHEAL FARADAY 1791 - 1864
 In 1831, Michael Faraday, using a simple magnet and a coil of wire,discovered that
mechanical energy could be converted into electrical energy,
NEWAGE PRODUCT TRAINING
SIMPLE FARADAY GENERATOR
ELECTRIC
LIGHT BULB
WATCH THE
LIGHT BULB !
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.
NEWAGE PRODUCT TRAINING
BASIC PRINCIPLES OF AN A.C GENERATOR
Permanent Magnet Field
Magnetic Field
(Flux)
N
Shaft
Copper
loop
+VE
Slip-rings
and Brushes
S
THIS TIME THE
MAGNETS ARE
STATIONARY, BUT THE
COIL IS MOVING !
Output
0
-VE
A.C Sinusoidal Output Voltage with A Permanent Magnet Field
NEWAGE PRODUCT TRAINING
BASIC PRINCIPLES OF AN A.C GENERATOR
Magnetic Field
(Flux)
Electro- Magnetic
Field
ADJUSTABLE
D.C SUPPLY
Shaft
Copper
loop
+VE
Slip-rings
and Brushes
Output
0
-VE
By controlling the D.C current into the magnetic field, the voltage level can be
adjusted, allowing control of the output voltage.
NEWAGE PRODUCT TRAINING
SIMPLE A.C GENERATOR
AIR GAP
(MAGNETIC
LINES OF
FORCE OR
FLUX)
ELECTRO
MAGNETIC
FIELD
D.C FIELD POLES
A.C OUTPUT
CARBON
BRUSHE
S
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.
NEWAGE PRODUCT TRAINING
WHY DO WE CHOOSE A.C, AND NOT D.C ?
Magnetic Lines
of Force
(Alternating
flux)
THE TRANSFORMER
Laminated
Steel Core
Primary
Winding
(Input)
Secondary
Winding
(Output)
A.C can be increased or decreased by means of MUTUAL INDUCTION.
 This is achieved by the TRANSFORMER, and is essential for POWER DISTRIBUTION.
 SECONDARY VOLTAGE = RATIO OF PRIMARY TURNS : SECONDARY TURNS
 The A.C transformer enables us to distribute A.C POWER over very large distances.
 D.C cannot be transformed, and can only be distributed at the generated voltage.
WHY IS THIS IMPORTANT ?
NEWAGE PRODUCT TRAINING
DISTRIBUTION OF A.C POWER
MAINS SUPPLY
A.C GENERATOR
STEP UP
TRANSFORMER
SUPER HIGH
TENSION
CB
400,000V
MCB
STEP DOWN
TRANSFORMER
MCB
 A.C Voltage can be increased or decreased by transformers,
 By increasing the Voltage, overhead supply cables can be made much lighter.
This allows load currents to be distributed over long distances at very high voltages.
NEWAGE PRODUCT TRAINING
TYPICAL ROTATING ARMATURE A.C GENERATOR
MAGNETIC
FLUX
D.C FIELD POLES
CARBON
BRUSHES
OUTPUT A.C
A.C.ARMATURE
SHAFT
BEARINGS
SLIPRINGS
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
NEWAGE PRODUCT TRAINING
TYPICAL ROTATING D.C FIELD GENERATOR
OUTPUT A.C
CARBON
BRUSHES
A.C STATOR
MAGNETIC
FLUX
SHAFT
D.C SUPPLY
D.C.FIELD (ROTOR)
BEARINGS
SLIPRINGS
 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
NEWAGE PRODUCT TRAINING
TYPICAL BRUSHLESS A.C GENERATOR
RECTIFIER
DIODES
OUTPUT A.C
MAGNETIC
FLUX
A.C STATOR
SHAFT
D.C.FIELD (ROTOR)
EXCITER ROTOR
EXCITER STATOR
BEARINGS
 The SLIPRINGS and BRUSHES are now replaced with : The RECTIFYER ASSEMBLY which converts A.C VOLTAGE into D.C VOLTAGE.
 The EXCITER ROTOR, which provides A.C POWER to the RECTIFIER.
 The EXCITER STATOR, which is the ELECTRO-MAGNETIC FIELD for the
EXCITER ROTOR.
 NOW LETS SEE HOW A BRUSHLESS GENERATOR WORKS
NEWAGE PRODUCT TRAINING
BRUSHLESS GENERATOR COMPONENT ASSEMBLY (TWO BEARING)
Main Rotor
Main Stator
Exciter Rotor
Exciter Stator
Bearing
Cartridge
N.D.E
Fan
Bearing
Cartridge
D.E
Key
Shaft
P.M.G
Rotor
P.M.G
Stator
Rectifier
NEWAGE PRODUCT TRAINING
BRUSHLESS GENERATOR COMPONENT ASSEMBLY (SINGLE BEARING)
Main Rotor
Main Stator
Exciter Rotor
Exciter Stator
Fan
Single bearing
Coupling
Bearing
Cartridge
N.D.E
P.M.G
Rotor
P.M.G
Stator
Rectifier
NEWAGE PRODUCT TRAINING
Main
Terminals
A.V.R.
on A.V.M,s
Non drive
end Bracket
& Exciter
Stator assy
HC Generator Assembly
Main Rotor
Main Stator
Fabricated
Frame
Drive end
Bracket
P.M.G
Rotor
P.M.G
Stator
NEWAGE PRODUCT TRAINING
Air flow through Generator
 Air flow must not be restricted
NEWAGE PRODUCT TRAINING
NEWAGE PRODUCT TRAINING
Excitation System
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
NEWAGE PRODUCT TRAINING
Excitation System - Exciter Stator
Exciter
Stator
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
NEWAGE PRODUCT TRAINING
Excitation System - Wound Exciter Stator
X+ (F1)
XX- (F2)
To A.V.R Terminals
COIL CONNECTIONS
N
S
N
S
 High-remanence steel core
 Stores Residual Magnetism
 12-14 pole magnet field
 High frequency Generator
NEWAGE PRODUCT TRAINING
Excitation System - Exciter Rotor
Exciter
Rotor
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
NEWAGE PRODUCT TRAINING
Excitation system - Exciter Rotor Assembly
W
U
V
SHAFT
V
U
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.
NEWAGE PRODUCT TRAINING
Excitation System - Exciter Rotor/ Main Rectifier
Exciter Rotor and
Main Rectifier
Circuit
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
NEWAGE PRODUCT TRAINING
Exciter Rotor and Rectifier Assembly
 Wound Exciter Rotor
W
U
 Rectifier Assembly
V
SHAFT
SHAFT
V
U
W
 Rectifier Assembly Mounted on Exciter rotor Core, (drive end side).
 NOTE: BC & Frame 8 Generators are mounted at the non-drive end side.
NEWAGE PRODUCT TRAINING
Exciter Rotor & Main Rectifier Assembly
Exciter Rotor 3 Phase
with Internal Star Point
SHAFT
NEWAGE PRODUCT TRAINING
Exciter Rotor & Main Rectifier Connections
 Rectifier Input Terminal
SHAFT
SHAFT
 3 Phase A.C Exciter Rotor Connected to Rectifier input terminals
NEWAGE PRODUCT TRAINING
Excitation System - The Main Rectifier
Main
Rectifier
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
NEWAGE PRODUCT TRAINING
The Main Rectifier Assembly
 3 Phase A.C Input
from Exciter Rotor.
(Insulated Terminals)
 Aluminium
Heat-sinks
 Varistors
(Surge Suppressors)
 Rectifier Hub
 Rectifier Diodes
Negative Plate
Anode Stud
SHAFT
 Rectifier Diodes
Positive Plate
Cathode Stud
 Output to
Main Rotor
NEWAGE PRODUCT TRAINING
Main Rectifier Assembly- Operation of a Diode
+VE
 A.C Input to Rectifier
Diodes
 Rectifier Diode
Positive Heatsink
Cathode Stud
+
0
-VE
+VE
0
-VE
 Rectifier Diode
Negative Heatsink
Anode Stud
+VE
0
-VE
 for a 12 pole exciter field the frequency will be 150 or 180 HZ
(cycles/second).
NEWAGE PRODUCT TRAINING
Main Rectifier Assembly- 3 Phase Rectification
 A.C Input to Rectifier
Diodes
 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
NEWAGE PRODUCT TRAINING
Metal Oxide Varistor (Surge Suppressor)
 UC & BC Type 350 Volt
 Clamping @ 30 Amp 680 Volts
 HC & F8 Type 778 Volt
 Clamping @ 100 Amp 1365 Volts
Diode Protection Device
For Transient Suppression
SHAFT
Main Rotor
Connections
SHAFT
NEWAGE PRODUCT TRAINING
Metal Oxide Varistor (Surge Suppressor)
DIODE PROTECTION DEVICE
Direction of transient
 Energy absorbed
by Varistor.
 Varistor clamping
(Protection) level.
Full load D.C
output from
main Rectifier
t = µ sec's.
Typical high voltage transient created by
fault condition in the distribution system.
Up to 2- 3000V (peak voltage)
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.
D.C supply
to Main
rotor
NEWAGE PRODUCT TRAINING
Excitation System - The Main Rotor
Main Rotor
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
NEWAGE PRODUCT TRAINING
Main Rectifier Connections to Main Rotor
Main Rectifier
 Aluminium
Heat-sinks
SHAFT
Main Rotor
D.C
 The Rectifier Output is a smooth D.C Supply across the Aluminium Heat Sinks
 This is fed to the Main Rotor windings
NEWAGE PRODUCT TRAINING
Wound Main Rotor - Coil Group connections
ANTI CLOCK
D.C Input
From Main
Rectifier
S
CLOCK
N
N
CLOCK
S
ANTI CLOCK
 The Rotor coils are connected in Series (4 Pole Rotor shown).
 Each coil is reversed to the adjacent coil, producing the required polarity
NEWAGE PRODUCT TRAINING
Wound Main Rotor - Poles & Frequency
Generator Frequency (HZ) = Speed (N) X Pairs of poles (P)
60
6 Pole Available
in Frame 7
4 Pole
SHAFT
N
N
N
S
2 Pole
SHAFT
NEWAGE PRODUCT TRAINING
Wound Main Rotor - Poles & Frequency
 Main Stator Core
(section)
 Main Stator Coils in Slots (section)
 4 Pole Main Rotor
 Air Gap
N
SHAFT
N
S
 1 Cycle
 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
NEWAGE PRODUCT TRAINING
Wound Main Rotor - Poles & Frequency
 Main Stator Coils in Slots
 Main Stator Core
 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.
NEWAGE PRODUCT TRAINING
Wound Main Rotor - Poles & Frequency
 Main Stator Core
 Main Stator Coils in Slots
 4 Pole Main Rotor
 Air Gap
S
SHAFT
S
N
1 Cycle
 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.
NEWAGE PRODUCT TRAINING
Wound Main Rotor - Poles & Frequency
Generator Frequency (HZ or CYCLES) = Speed (N) X Pairs of poles (P)
60
FRQUENCY
NUMBER
ENGINE
HZ (CYCLES)
POLES (P)
SPEED (N)
50
2
3000
50
4
1500
50
6
1000
60
2
3600
60
4
1800
60
6
1200
2 Pole 1 HZ = 60 RPM
4 Pole 1 HZ = 30 RPM
6 Pole 1 HZ = 20 RPM
NEWAGE PRODUCT TRAINING
Main Rotor- Amortisseur (Damper) Windings
SHAFT
 Amortisseur Winding (Damper Bars)
(Aluminium Damper Bars Welded to End Plates )
N
N
S
NEWAGE PRODUCT TRAINING
Main Rotor- Amortisseur (Damper) Windings
 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
NEWAGE PRODUCT TRAINING
Operation - Main Stator
Main Stator
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
NEWAGE PRODUCT TRAINING
Wound Main Stator Assembly
 The Main stator insulation is class H as standard, allowing up to 165º C temperature.
 The laminated core is built from high grade Electrical Steel to minimise Iron losses.
 12 Ends Out Re-connectable, or 6 Ends out Star / Delta, or Dedicated Windings.
 Windings are standard for most voltages, special windings required for some
voltages
Output Leads
Laminated Steel core
Copper Windings
NEWAGE PRODUCT TRAINING
Wound Main Stator Assembly
 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
L
Output Leads
Copper Windings
Laminated Steel core
NEWAGE PRODUCT TRAINING
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.
NEWAGE PRODUCT TRAINING
Typical Main Stator 12 Wire Re-connectable
2/3RDS PITCH
8 SLOTS
( SPAN 1 TO 9)
WINDING LEADS
START OF COIL
GROUP
ONE PHASE GROUP
( 4 COILS PER GROUP)
WINDING LEADS
FINISH OF COIL
GROUP
FULL PITCH
12 SLOTS
( SPAN 1 - 13)
MAIN ROTOR
(4 POLE)
SHAFT
N
N
S
MAIN STATOR WINDING
SECTION ( 48 SLOT )
NEWAGE PRODUCT TRAINING
Typical Main Stator 12 Wire Re-connectable
 Connections shown in Series Star
N
6
AVR Sensing
& Power supply 7
from Main Stator
8
W
V6
Neutral
W1
3 Phase Output
V
V1
U
U1
NEWAGE PRODUCT TRAINING
Wound Main Stator 12 Wire Re-connectable
Parallel Star
Series Star
Voltage Range (winding 311)
380 to 440 V @ 50 HZ
416 to 480 V @ 60 HZ
Voltage Range (winding 311)
190 to 220 V @ 50 HZ
208 to 240 V @ 60 HZ
U
U
8
U1
U2
W6
U5
U6
w
U2
U6
N
N
W2
V6
V2
W2
W1
U5
8
V6
6
U1
V5
W1
W5
7
V5
V1
6
v
w
W6 V2
W5
V1
7
v
 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.
NEWAGE PRODUCT TRAINING
Wound Main Stator 12 Wire Re-connectable
Series Delta
Centre
Tap
6
Double Delta
6
8
7
7
8
N
Voltage Range (winding 311)
220 to 250 V @ 50 HZ, 240 to 277 V @ 60 HZ
No Neutral connection.
Centre Tap for low volts 1ph only
Voltage Range (Winding 311)
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
NEWAGE PRODUCT TRAINING
Wound Main Stator 6 Ends Out
Star
U
8
Voltage Range (winding 312)
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
Number of Stator leads in parallel
multiply’s with current rating
of generator,
ie: 12, 18, 24, 36, or 48 leads out.
U1
U2
N
W2
6 W1
w
V2
7
V1
v
Each phase group is producing the full line voltage, (all coil groups in each phase are in
parallel).
NEWAGE PRODUCT TRAINING
AVR INPUT TERMINALS - SENSING SUPPLY
Sensing Supply to A.V.R for 6 ends out STAR connected
U
Examples - 6 ends Stators
Winding 312
380 to 440 V @ 50 HZ
416 to 480 V @ 60 HZ
Single Phase (N) = 3 of L-L
8
U1
Isolation transformer
U2
Winding 26
660 - 690 Volts @ 50 HZ
8
N
W2
W1
V2
V1
7
v
w
6
7
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
NEWAGE PRODUCT TRAINING
Excitation Control - Automatic Voltage Regulator (A.V.R)
The A.V.R
A.V.R
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
NEWAGE PRODUCT TRAINING
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
NEWAGE PRODUCT TRAINING
Automatic Voltage Regulator (AVR) Type SX460/2 (Self -Excited)
VOLTS
X XX 6
7
8
1
2
3
4
WARNING!
ELECTRIC SHOCK
[Live Terminals]
UFRO
50HZ
C
60HZ
STABILITY
NEWAGE PRODUCT TRAINING
Automatic Voltage Regulator (AVR) Type SX440 (Self Excited)
3
2
2 1
TRIM
WARNING!
ELECTRIC SHOCK
[Live Terminals]
DROOP
VOLTS
UFRO
50 C 60
STABILITY
Input Var/ PFC3
Input Droop C/T
8 7 6 5 4 3 2 1
X
S2 S1 A2 A1
P4 XX
8 7 6 5 4 3 2 1
K2 K1 P2 P3
Linking for
3 Phase
Sensing Unit
C B A
NEWAGE PRODUCT TRAINING
Automatic Voltage Regulator (AVR) Type MX341 P/N E000-23412/1P
3
2
2 1
TRIM
WARNING!
ELECTRIC SHOCK
[Live Terminals]
MX341-2 E000-23412
DROOP
VOLTS
8 7 6 5 4 3 2 1
X
S2 S1 A2 A1
P4 XX
8 7 6 5 4 3 2 1
K2 K1 P2 P3
Linking for
3 Phase
Sensing Unit
EXC
TRIP
DIP
STABILITY
UFRO
3
1
2
C B A
NEWAGE PRODUCT TRAINING
Automatic Voltage Regulator (AVR) Type MX321 P/N E000 -23212
P4
K2 K1 P2 P3
XX X 6
P4
7
8
1 2
VOLTS
RAMP
I /LIMIT
FREQUECY
SELECTION
UFRO
3
2
1
DIP
R.M.S
DWELL
STABILITY
STABILITY
SELECTION
U
OVER/VOLT
EXC TRIP
E0 E1 B0 B1
C
V
W
DROOP TRIM
S1 S2 S1 S2 S1 S2 A1 A2
B
A
NEWAGE PRODUCT TRAINING
Operation of AVR - as an electronic switch
 DIODE CIRCUIT
 SILICON CONTROLLED RECTIFIER (SCR)
Gate
A.C Power
Supply
AVR
Control
Circuit
A.C Power
Supply
X
1/2 Wave D.C
1/2 Wave D.C
Exciter field
Exciter field
 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.
NEWAGE PRODUCT TRAINING
Operation of AVR - as an electronic switch
D.C Pulses
From A.V.R Into
Exciter Stator
X+ (F1)
A.V.R
 A.C power supply from
Main Stator
 Sensing Supply
(2 or 3 phase)
XX- (F2)
Exciter
Rotor
& Stator
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.
NEWAGE PRODUCT TRAINING
Operation of AVR - as an electronic switch
Phase Control of AVR power supply (Self Excited)
AC power supply to
AVR 170 to 240V.
50 or 60 HZ .
D.C Power supply (1/2 cycle rectification)
Power ON
After time (T)
OFF
OFF
 Number of pulses are the same as the A.C power
supply frequency (50 or 60/second)
 NO LOAD D.C Pulses into the Exciter Stator X+(F1) XX-(F2)
(T)
 The power device (Thyristor or SCR) is switched ON by the control
circuit, after time delay (T).
 The Thyristor automatically switches OFF as the power supply pulse
falls to zero after each cycle.
NEWAGE PRODUCT TRAINING
Operation of AVR - as an electronic switch
Phase Control of AVR power supply (Self Excited)
Power ON
After time
(T)
OF
F
OF
F
(T)
 FULL LOAD D.C Pulses into the Exciter Stator X+(F1) XX-(F2)
 As LOAD is increased , the time delay (T), will automatically decrease.
 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.
NEWAGE PRODUCT TRAINING
Operation of AVR - as an electronic switch
Phase Control of AVR power supply (Self Excited)
Power ON
After time (T)
OFF
OFF
(T)
 OVERLOAD D.C Pulses into the Exciter Stator X+(F1) XX-(F2)
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.
NEWAGE PRODUCT TRAINING
Excitation System - Separately Excited Generators
The Permanent Magnet Generator
(PMG)
P2, P3, P4 Power Supply To A.V.R
 Generator Shaft (Non-Drive -End)
 Dowel Pin for PMG Rotor Location
 Ceramic Magnet Rotor, highly magnetic saturated field. 8 Pole Rotor , 100 HZ
(at 1500 RPM ) or 120 HZ (at 1800 RPM )
 Through Bolt fixture to Shaft non drive end
 Permanent Magnet Stator 3 Phase A.C 170 to 220 Volts, separate power
supply for the A.V.R
NEWAGE PRODUCT TRAINING
P.M.G Assembly UC Frame sizes
NEWAGE PRODUCT TRAINING
PMG Rotor & Stator Assembly - HC Frames
 Optional on HC4,& HC5
 3 Phase A.C, 170- 220 Volts
P.M.G
Rotor
P.M.G
Stator
in Housing
NEWAGE PRODUCT TRAINING
Excitation System - Separately Excited Generators
PMG
Power
Supply
To A.V.R
P2 -P3 -P4
X+ (F1)
A.V.R
A.C Feedback
Signal only.
(Sensing)
from Stator
6-7-8
XX- (F2)
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
NEWAGE PRODUCT TRAINING
Excitation System - Separately Excited Generators
 Advantages of the PMG System
 The PMG is a separate power supply for AVR, which is
unaffected by adverse loading conditions such as :Waveform distortion caused by non linear loads
Transient fault conditions in the distribution system.
 Provides a powerful voltage build up system on initial runup, (does not rely upon residual magnetism)
 Provides sustained short circuit current under fault
conditions, (requirement for all Marine classifications).
NEWAGE PRODUCT TRAINING
NEWAGE PRODUCT TRAINING