ApplicationNotes Information from the Application Engineers at Waukesha Engine/Waukesha Power Systems

No. WPS2/88A

GENERATOR SELECTION AND OPTIONS

Waukesha Enginator® engine-generator sets supply electrical
power to users in North America and worldwide. Because electri-
cal system requirements very greatly among different locations
and installations, making the choices of generator and optional
equipment is a crucial part of specifying the complete Enginator®.
This Application Note reviews the critical issues in basic gen-
erator selection and especially the various options that can be
added to the generator to meet the special requirements of an
installation.
Note: the standard generators on Waukesha Enginator® systems
is AC synchronous type, 480 volt, 3 phase, 60 Hz, (or 400 volt,
3 phase, 50 Hz), 4 wire, WYE connected, with temperature rise
within NEMA (105°C) for prime power duty, within NEMA (130°C)
for continuous standby duty.

generator selection
The generator model is selected in light of the power generation
and site requirements outlined in the following list. These items
are relatively easy to determine from the application or from the
customer’s specifications, and they form the basis for the com- Table 1.
plete generator description.
AMBIENT TEMPERATURE
ALTITUDE
Generator Type - Synchronous or Induction, AC or DC. FOR STANDARD

Speed - Generator RPM, (same as engine RPM for direct- 0-3300 ft (0-1000 m) 104°F (40°C)
coupled units). 330-8500 ft (1001-2600 m) 77°F (25°C)
Frequency - Typically 50 or 60 Hz. 8501-11200 ft (2601-3400 m) 59°F (15°C)

Voltage generator options

Phase - Single phase or three phase.
kW Rating - Sized according to the loads to be supplied, which
may be resistive, inductive, SCR type, motor starting, or others.
Power Factor - 0.8 is generally used for rating purposes.
Temperature Rise - At the rated kW (or KVA).
Connection Type - WYE, Delta, reconnectable or other.
Number Of Wires - 3, 4, 6, 10, or 12.
Winding Pitch - 2/3 pitch is often specified to minimize 3rd order
harmonics on units operating in parallel with the utility.
Number Of Bearings - 1 or 2. Generally, single bearing genera-
tors are preferred, however, sixteen cylinder VHP engines require
the use of 2 bearing generators, and induction generators may
require 2 bearings.
Derating Factors - Altitude and Temperature - At altitudes above
3300 ft and temperatures above those listed in Table 1, generator
derating may be necessary due to diminished generator cooling.
Once the basic generator has been selected, a number of options
can be added to meet the special requirements of an installation.
Following are descriptions of some common generator options,
and situations in which they are typically used:
Air Filter - Mounts directly to the generator cooling air inlet, to
filter the incoming air. Used in extremely dusty or abrasive en-
vironments.
Cross Current Compensation - Controls reactive load and is
required for parallel operation. Includes current transformer.
Enclosures - Drip covers and shrouds for splash protection
can be supplied, as well as various types of NEMA enclosures
including Open Drip Proof (ODP), Totally Enclosed Air Over
(TEAO), Totally Enclosed Fan Cooled (TEFC), Air-to-air Heat
Exchanger.
Oversize Junction Box - Often specified when current trans-
formers and other accessories are to be mounted in the junction
box instead of in the switchgear.
Note: Due to space limitations, not all combinations of mounted
accessories will fit, even in an oversize junction box. Wire size is
also a factor in selecting an oversize junction box.
 ApplicationNotes
Short Circuit Sustain - Allows the generator to sustain short
circuit (fault) currents for selective tripping of circuit breakers, as
well as assisting the voltage regulator during heavy motor start-
ing loads. The usual requirement is to maintain 300% of rated
generator current for 10 seconds, for a generator with 80°C or a
105°C temperature rise. (A 130°C rise generator may maintain
somewhat less current.) Three types are available:
• Permanent Magnet Generator (PMG) - This is a small
generator driven directly off of the main generator shaft.
It provides an independent source of voltage regulator
power, sustains short circuit, and provides field flashing.
This is the preferred type of short circuit sustain, as large
current transformers are not necessary.
• Series Boost Option (SBO) - Consists of a reservoir as-
sembly and one or two current transformers for mounting
in the switchgear or generator junction box.
• Current Boost System (CBS) - Consists of a current boost
module and one or two transformers for mounting in the
switchgear or generator junction box.
Note: PMG or SBO should be specified when SCR loads
(UPS) are connected to the generator in order to limit EMI
and RFI influence on the voltage regulator.
Space Heaters - Keep the generator windings dry in areas of
high humidity, such as marine or tropical service. Generally 120
or 240 volt, single phase, AC.
Terminal Standoff Connectors - Located in the generator junc-
tion box to provide a solid mounting location for the generator
output leads, along with a rigid connection point for the customer
leads.
Temperature Detectors, Winding and Bearing - Generator
windings and bearings can be fitted with resistance temperature
detectors (RTD’s) (10 ohm copper, 100 ohm platinum, or 120
ohm nickel) or thermocouples (type J or type K) to monitor inter-
nal generator temperatures for overload or impending damage
conditions. Temperature signals can be fed to a readout-only, or
to a signal processor to provide warning or shutdown contacts.
Thermal switches that open at a given temperature can also be
embedded in the windings of some generators.
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Testing - Standard commercial tests for synchronous generators
routinely include the following tests, conducted in accordance
with IEEE-115 and NEMA MG-1:
• Resistance of all windings (cold).
• Insulation resistance of all windings.
• High potential on all windings.
• Open circuit saturation.
• Voltage balance on windings.
• Current balance on windings.
• Voltage transient at rated KVA (voltage regulation, stability
and response).
• Regulator range test (voltage adjust).
• Phase sequence.
• Mechanical balance (vibration).
• Inherent voltage regulation.
• Three phase build-up short circuit (if PMG or SBO is
supplied.
• Circulating current (when applicable).
Special testing beyond the generator manufacturer’s standard
commercial testing can be supplied, for example to meet Military
Standard 705b.
Transformers - Current transformers (CTs) for metering and/or
fault protection can be supplied for mounting in the generator
junction box or switchgear. Potential transformers (PTs) should
be mounted in the switchgear.
Voltage Regulators - Special features that are available on volt-
age regulators include: Closer regulation (1/2% or better), Volts
per hertz regulation, Three phase sensing, Radio Frequency
Interference (RFI) filters.
Consult your local Waukesha Distributor for system application assistance. The manufacturer re-
serves the right to change or modify without notice, the design or equipment specifications as herein
set forth without incurring any obligation either with respect to equipment previously sold or in the
process of construction except where otherwise specifically guaranteed by the manufacturer.