Taking winding connection data on alternators
Properly gathering, recording information will pay off in the long run
By Tom Bishop, P.E.
EASA Senior Technical Support Specialist
We will begin this article by clarify-
ing the terms “alternator” and “gen-
erator.” Both terms refer to a machine
that converts mechanical to electrical
power. An alternator is a synchronous
machine that converts mechanical to
AC electrical power. A generator is a
more general term and is a machine
that converts mechanical to electrical
power, either AC or DC. An alternator
is always a generator, but not vice-
versa. Our focus in this article will
be on 3-phase alternators. However,
much of the information provided also
applies to single-phase alternators and
single- or three-phase generators.
Identify the leads
The initial step in the rewind data
taking process is to determine the
number of leads and their identifi-
cation. Consider this example: The
main stator of an alternator has 10
leads, with numbers 0 through 9. See
Figure 1. The “0” lead is probably the
neutral; however, the lead identifica-
tion should be verified. If that is the
case, the alternator has an internal
wye or multiple internal wyes and the
lead coming from it is labeled “0.” To
confirm this, we need a low-resistance
ohmmeter. There will be continuity
between the four leads 7-8-9-0, and
May 2010 • EASA CURRENTS
between each pair 1-4,
2-5, 3-6. The resistance
from leads 7, 8 or 9 to lead 1
0 should all be the same
and should match that 4
of leads 1-4, 2-5, and 3-6.
There will be continuity 7
between leads 7, 8, 9 and 0
and the resistance between
leads 7-8, 8-9 and 9-7 will
9 85
be twice the values of the
previous test.
6
Many large alternators
3 0 2
have 12 or 24 external
leads. For the purposes of
using EASA’s internal con-
nection diagrams, these
can be considered wye- Figure 1. Lead numbering for a 10-lead alternator.
delta 12-lead connections.
The 24 leads consist of
leads that will be paired
to result in 12 leads. Al-
though most alternators
utilize external wye con-
nections (to provide a neu-
tral), there are cases where
the alternator output is
delta connected. These
possibilities reinforce the
need to carefully record
the complete as-received
connections. See Figure 2.
If there are leads in addi-
tion to the main winding
output, they may be taps Figure 2. Note the apparent random arrangement of leads
used to provide voltage for and connections, necessitating great care when
control circuits such as for recording the connections.
the voltage regulator. See
the section on determining the inter- size that would be determined from
nal connections for further guidance. a lead wire ampacity table. This is
Note: Numerical lead labeling particularly the case with alternators
is common with North American rated for less than continuous, e.g.,
alternators, and alphabetical (letter) standby duty. Record the as-received
or alphanumeric lead identifications lead wire size if it is marked on the
are commonly found on alternators leads. If the leads are not marked, slip
manufactured to IEC standards. a terminal lug that fits snugly onto the
leads, thereby using the lug as sizing
Determining lead wire size guide to determine the correct lead
The lead wire size used on an al-
ternator is frequently smaller than the
Continued On Page 2
Copyright © 2007-2010 Electrical Apparatus Services Association, Inc. 1
Taking winding connection data on alternators
Properly gathering, recording information will pay off in the long run
Continued From Page 1

wire size. Note: Lugs are not sized for ficult and frequently
lead cable, so the correct lug will be not possible. It is much
snug to very tight. better to carefully take
connection data rather
Determine the internal than have to purchase
connections a replacement stator
Prior to the burnout process, it is or complete alterna-
a good practice to lift and completely tor if the correct and
identify the connections. If there are complete connection
leads other than output power leads, information was not
such as main winding taps for a control obtained during the
circuit or leads for an auxiliary wind- data taking process.
ing, these need to be identified, and After identifying
their position in the winding located. and labeling all of the
See Figures 3 and 4. Label every lead: main external leads
main winding, taps, auxiliary, etc. with from the winding, pro-
identification that will withstand the ceed to do the same
burnout process. with any taps or aux-
Draw the winding connection be- iliary winding leads.
fore the burnout process and verify If there are taps, count
that it is correct. Most but not all al- the number of coils Figure 3. Example of an alternator with 10 main leads and
ternators are synchronous machines between the tap and
4 tapped connections (20, 22, 24 and X1).
having a rotor with wound poles the associated main
supplied by direct current (DC). A lead. Likewise, count
straightforward but important check the number of coils
is to confirm that the winding poles from the tap to the
match the number of wound poles on nearest non-output
the synchronous rotor. lead, most often a
Connection data for alternators is lead that is used to
frequently not available from the origi- form a wye connec-
nal manufacturer. In some cases the tion. In many cases
manufacturer name on the alternator the tap is within a coil.
nameplate is not the actual alternator Therefore, count the
manufacturer, making the task of ob- number of turns to the
taining original information more dif- tap. See the July 2004
Currents article titled
It is much better to “Powering Up: Deter-
mining Where To Tap
carefully take con- Stator Windings” for
nection data rather detailed instructions
than have to purchase to identify and locate
a replacement stator tap locations. Note: If Figure 4: An alternator with 12 main leads and 6 tapped
the winding is tapped, connections.
or complete alterna-
it may be prudent to
tor if the correct and Draw the connection diagrams of the
burn out the stator without first cut-
complete connection ting off the coil end. main and auxiliary windings referenc-
information was not If there is an auxiliary winding, ing coil and lead positions relative to
obtained during the data permanently label a slot as “slot #1.” A slot #1. Relative to the main winding,
taking process. good place to do this is the slot where and to slot #1, the auxiliary winding
the main winding lead #1 is located. Continued On Page 3

2 May 2010 • EASA CURRENTS Copyright © 2007-2010 Electrical Apparatus Services Association, Inc.
Taking winding connection data on alternators
Properly gathering, recording information will pay off in the long run
Continued From Page 2
should be inserted in the same slots.
For example, if the auxiliary winding
begins in the same slot as coil #1 of the
main winding, it should be reinserted
in the same slot as coil #1 of the main
winding. The auxiliary winding is
the secondary of a transformer with
the main winding being the primary.
If the auxiliary winding is not cor-
rectly placed back in the stator it may
develop an incorrect output voltage
and the alternator will not perform
properly.
Current density
When checking the lead wire size,
also count and measure the winding
coil wires and calculate the wire area
per amp. The winding wire area per
amp (CMA) will often be less than
typical for motors, especially if the
alternator is rated for standby duty.
If the current density is found to be
less than about 275 CMA, check the
nameplate to be certain the machine
is rated for standby duty. Continu-
ous duty alternators typically have
current densities above 300 CMA. If
slot space allows, wire area per turn
can be increased. The winding will
operate cooler and be more efficient
with the larger wire area.
Winding changes
In general, it is best to maintain
the original winding data. This may
not be possible when converting
metric to AWG wire sizes or half to
full size wire gauges. However, this
Table 1. Slots and fractional pitches for a 4-pole alternator.
Slots 2/3 pitch 4/5 pitch
36 1-7 n/a
48 1-9 n/a
54 1-10 n/a
60 1-11 1-13
72 1-13 n/a
84 1-15 n/a
96 1-17 n/a
May 2010 • EASA CURRENTS
type of conversion is satisfactory if
wire area per turn is maintained or Another consideration
increased, provided the slot fit is not is that paralleled alterna-
made too tight. The coils should fit
tors often need to have
snugly in the slots; if too tight, a short
could result. the same pitch to pro-
Concentric to lap changes can be vide matching output
performed, but with caution. It may waveforms. Changing
not be enough to have the lap wind- the pitch could cause
ing match the magnetic flux densities sensitive load or protec-
of the original concentric winding.
The lap span must be equivalent to
tive circuits to reject the
the concentric. For example, some alternator output and
alternator windings use 2/3, 4/5, 6/7 not allow the alternator
or 5/6 pitch. The 2/3 pitch is used to operate. The same
to eliminate third harmonic content
caution applies to an
in the output; the 4/5 eliminates the original lap winding; that
fifth harmonic; the 6/7 eliminates the
seventh harmonic: and the 5/6 pitch
is, the span should not
reduces the 5th and 7th harmonics. be changed.
Table 1 illustrates the combination of
slots and pitch that can be used with
(5+7+9+11 = 32/4 =8). With 48 slots
a 4-pole alternator. Note that while
and 4 poles, full pitch is 12 (48/12).
the 2/3 pitch is common to all slot
The winding pitch is 8/12, or 2/3.
combinations in the table, the other
The chord factor of the 2/3 pitch
useable fractional pitches occur much
winding is 0.866, lower than normal
less frequently.
for a 4-pole winding. Our training
Another consideration is that par-
with winding design inclines us to
alleled alternators often need to have
increase the span to a chord factor
the same pitch to provide matching
greater than 0.900. Doing so may
output waveforms. Changing the
also allow a reduction in turns and
pitch could cause sensitive load or
an increase in wire area. That would
protective circuits to reject the alterna-
reduce winding losses and result in
tor output and not allow the alterna-
cooler operation, except that the span
tor to operate. The same caution ap-
change may not allow the alternator
plies to an original lap winding; that
to connect to the line or parallel with
is, the span should not be changed.
other alternators. As tempting as an
How is the lap span made the
increase in span may seem, we need to
equivalent of
maintain the original equivalent span
the concentric
so as not to create difficulties.
5/6 pitch 6/7 pitch span? Here is
Occasionally the wires in multiple
an example:
n/a n/a are much more than may be on hand
4-pole wind-
1-11 n/a or that the winding machine can
ing, 48 slots,
pull. If the number of circuits can be
n/a n/a spans 1-6-8-
doubled, that will reduce the area of
n/a n/a 10-12. The
wires in multiple by 50%. However,
teeth spanned
1-16 n/a check that the volts per coil do not
a re 5 - 7 - 9 - 11 ,
n/a 1-19 exceed about 80 volts. Also, maintain
with an aver-
1-21 n/a age value of 8 Continued On Page 4
Copyright © 2007-2010 Electrical Apparatus Services Association, Inc. 3
Taking winding connection data on alternators
Properly gathering, recording information will pay off in the long run
Continued From Page 2
the original type of connection, which
is usually wye for the 3-phase line-to-
line output. And check that the desired
number of new circuits is possible.
For example, if the original connec-
tion of a 6-pole generator was 2 wye,
a doubling to 4 wye would require an
impossible connection.
It is a good practice to use the
EASA AC Motor Verification and
Redesign Program when performing
changes such as doubling the circuits
to reduce wires in multiple. The pro-
gram has built-in checks to prevent
selection of circuits that can’t be used.
It also confirms that the magnetic flux
4 May 2010 • EASA CURRENTS
and current densities are maintained.
One practical alternative solution is to
wind two sets of coils, each using half
the needed wires in hand, lay them in
exactly the same slots, then parallel
the two sets.
Voltage changes
Proceed cautiously with requests to
change the voltage rating of an alterna-
tor. If the machine is rated 600 volts or
less, a change to a higher voltage such as
4160 volts will probably not be feasible
even if the original winding had formed
coils. The reason is that the higher volt-
age rating requires much more coil to
ground insulation, thus reducing the
Copyright © 2007-2010 Electrical Apparatus Services Association, Inc.
CMA to a value that may be too low
even for standby duty. Voltage changes
from a higher voltage such as 4160 volts
to a lower voltage such as 480 volts
may also be problematic. The theoreti-
cal conversion often requires fractional
turns such as a combination of 1 and 2
turn coils that are not practical to use. A
coil with 2 turns would have only about
50% of the CMA of the 1 turn coil and
would probably overheat. In some cases
the conversion results in a fractional turn
much less than 1, making it impossible
to convert. n