Product Build - All

Frame Sizes
 Generator Ratings

kVA RATINGS AT 50 HZ P80

HC6
P7
HC5
HC4
UC27
UC22
BC18
BC16

16 42 85 250 400 675 1130

20 55 104
2200 4253
312 500 843 1438 2750 5190
kVA RATINGS AT 60 HZ
FOR KW RATING MULTIPLY X 0.8 POWER FACTOR

Ratings are 3 Phase, Class H, Continuous Base Load, at 40º Ambient

PRODUCT TRAINING
 Generator Ratings - Core Lengths

C,D,E,F,G,H.
Core lengths

5 Within each frame size, different core lengths ( L ) provide smaller KVA Rating changes.
5 EXAMPLE :- UC27 C,D,E,F,G,H. Core Lengths = 92.5 kVA to 250 kVA (@ 50 HZ)

PRODUCT TRAINING P.F

PRODUCT TRAINING
PRODUCT TRAINING
PRODUCT TRAINING
 Two Bearing Main Rotor Assembly

Main Rotor Fan

Exciter
Bearing Rotor Bearing
(Sealed for life) (Sealed for life)

Shaft

PMG Rotor
(Optional on UC)
Rectifier
(Non drive end
on BC range)

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 Single Bearing Main Rotor Assembly

Coupling Hub
Coupling Discs

5Drive End of Generator Shaft is supported by the Engine Flywheel

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 UC Range Generator Assembly
12 Wire Frame
Main
Reconnectable
Terminals Main Rotor Drive end
Main Stator Bracket

Non drive
end Bracket
& Exciter
Stator assy

Foot

PRODUCT TRAINING
 UC Range Generator Assembly

A.V.R. Terminal
on A.V.M,s Box

P.M.G P.M.G
Rotor Stator
(Optional on UC)

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PRODUCT TRAINING
PRODUCT TRAINING
PRODUCT TRAINING
 Main Rotor Assembly Two Bearing

Fan
Exciter Rotor Main Rotor (4 Pole)
Bearing Bearing
Cartridge Cartridge
N.D.E D.E

Key

Shaft
P.M.G
Rotor
Rectifier

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 Main Rotor Assembly Single Bearing

5Drive end of Generator supported by engine Flywheel Single bearing

coupling
5 Flexible coupling discs fit into flywheel Recess assembly

PRODUCT TRAINING
P7 Generator Assembly Main
Terminals
N W V U
Neutral Star Non drive
Point end Bracket
Drive Main Stator & Exciter
End Bracket PFC3 N A.V.R.
Fabricated Stator assy
Frame
Bearing Cap
P.M.G
Rotor

Main
Rotor

P.M.G
Stator

PRODUCT TRAINING
PRODUCT TRAINING
PRODUCT TRAINING
PRODUCT TRAINING
 Frame P80 Rotor Assembly - Two Bearing

Fan Hub
Fan
Exciter Rotor Main Rotor
Bearing Bearing
Cartridge Cartridge
N.D.E D.E

Shaft
P.M.G
Rotor Rectifier

PRODUCT TRAINING
 Frame P80 Rotor Assembly - Single Bearing

Coupling
Discs
Fan
Exciter Rotor Main Rotor
Bearing
Cartridge
N.D.E

P.M.G
Rotor Rectifier

Coupling Hub

PRODUCT TRAINING
 Frame P80 Drive End Assembly – 2 Bearing Assembly

Terminal
Box

Terminal
Box Saddle
Bearing
Master Drive Carrier
End Bracket
Bearing &
Feet Rotor Shaft

Main Bearing
Frame Cap
bolts

PRODUCT TRAINING
 Frame P80 Drive End Assembly – 1 Bearing Assembly

Terminal
Box

Terminal
Box Saddle
Single Bearing
Master Drive Bracket
End Bracket
Coupling Hub
Feet & Discs

Frame
bolts

PRODUCT TRAINING
 Frame P80 Complete Generator Assembly
Control Box Terminal
Access Box Assy
Panel U
V
5 Form Wound
N
Main Stator Winding Cable
Saddle
5WMain frame bars, (8) Entry
Glandplate
Permanent 5 Welded to core pack
Magnet Drive end
Generator Bracket

Frame Drive end

Covers Bearing
Support
Air
Inlet 5 Main Stator core
Cover

Bearing
Cap Main Rotor
Assembly

Non Drive end

Bracket & Exciter
Stator assembly Feet

PRODUCT TRAINING
Operation of
A.C Generators

PRODUCT TRAINING
PRODUCT TRAINING
 Excitation System - All Generator types

Main Stator
Exciter
Rotor
& Stator

Bearing

Main Rotor
Main Rotor Shaft

Rectifier
Fan

PRODUCT TRAINING
 Excitation System – Wound Exciter Stator

Exciter
Stator Main Stator
Exciter
Rotor
& Stator

Bearing

Main Rotor
Main Rotor Shaft

Rectifier
Fan

PRODUCT TRAINING
 Excitation System - Wound Exciter Stator

X+ (F1)
To A.V.R Output terminals
XX- (F2)

COIL CONNECTIONS

N S N S

5 High-remanence steel core

5 Stores Residual Magnetism
5 10 - 14 pole magnet field
5 High frequency Generator

PRODUCT TRAINING
 Excitation System – Wound Exciter Rotor

Exciter
Rotor
Main Stator
Exciter
Rotor
& Stator

Bearing

Main Rotor
Main Rotor Shaft

Rectifier
Fan

PRODUCT TRAINING
 Excitation system – Wound Exciter Rotor

W U

V
SHAFT V

W
5 3 Phase A.C output, each Phase connected to 2 diodes on Main Rectifier.
5 High Frequency output, ( from 10 to 14 Pole Exciter Stator ).
5 Exciter generator is a magnetic power amplifier supplying the main rotor current.

PRODUCT TRAINING
 Excitation System - Exciter Rotor/ Main Rectifier

Exciter Rotor and

Main Rectifier
Circuit

Main Stator
Exciter
Rotor
& Stator

Bearing

Main Rotor
Main Rotor Shaft

Rectifier
Fan

PRODUCT TRAINING
 Exciter Rotor & Main Rectifier Assembly

5 Wound Exciter Rotor

W U
5 A.C Input
connections 5 Rectifier Assembly

V
SHAFT
SHAFT V
5 D.C Output
connections

W
5 The Rectifier assembly is mounted on Exciter Rotor Core, (drive end side).
5 NOTE: BC & Frame 8 Generators are mounted at the non-drive end side.

PRODUCT TRAINING
 Exciter Rotor & Main Rectifier Connections

Exciter Rotor 3 Phase

with Internal Star Point

SHAFT

5 Each phase is connected to a positive and negative Diode

PRODUCT TRAINING
 Exciter Rotor & Main Rectifier Connections

Rectifier Output (D.C) Rectifier Input

To Main Rotor Terminals (A.C)

SHAFT
SHAFT

5 3 Phase A.C Exciter Rotor Connected to Rectifier input terminals

PRODUCT TRAINING
 Excitation System – the Exciter Generator & Main Rectifier
X+ (F1)
AVR
XX- (F2)
Rectifier
Assembly

Exciter
Rotor

SHAFT
SHAFT
Exciter
Stator

5 A.C output from the Exciter Rotor is rectified from A.C, to D.C, by the Main Rectifier assembly.

PRODUCT TRAINING
 Excitation System - The Main Rectifier

Main
Rectifier

Main Stator
Exciter
Rotor
& Stator

Bearing

Main Rotor
Main Rotor Shaft

Rectifier
Fan

PRODUCT TRAINING
 Main Rectifier Assembly UC/BC Type
5 UC/BC DIODE – MIN. 25 AMP 800 VOLT
5 3 Phase A.C Input
5 Aluminium
from Exciter Rotor.
Heat-sinks
(Insulated Terminals)

5 Split Two-Piece 5 Varistor

Rectifier Hub (Surge Suppressor)

5 Rectifier Diodes
Positive Plate
Cathode Stud SHAFT

5 Rectifier Diodes
Negative Plate
Anode Stud

PRODUCT TRAINING
 Main Rectifier Assembly- HC & F8 Type
5 HC4,5 DIODES – MIN. 36 AMP 1400 VOLT
5 HC6,P7, & F8 DIODE – MIN. 70 AMP 1400 VOLT
5 3 Phase A.C Input 5 Aluminium
from Exciter Rotor. Heat-sinks
(Insulated Terminals) 5 Varistors
(Surge Suppressors)
5 Rectifier Hub

5 Rectifier Diodes
Negative Plate
Anode Stud SHAFT

5 Rectifier Diodes
Positive Plate
5 Output to Cathode Stud
Main Rotor

PRODUCT TRAINING
 Main Rectifier Assembly- Operation of a Diode

+VE
5 A.C Input to Rectifier Diodes
( 150 HZ to 180 HZ per second)
0

5 Rectifier Diode -VE

Positive Heatsink
Cathode Stud
+VE

+ 0

-VE

5 Rectifier Diode
Negative Heatsink +VE
Anode Stud
0

-VE

PRODUCT TRAINING
 Main Rectifier Assembly- 3 Phase Rectification

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

5 D.C output to Main Rotor

+

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

PRODUCT TRAINING
 Metal Oxide Varistor (Surge Suppressor)

5 UC & BC Type 350 Volt 5 HC & F8 Type 778 Volt

5 Clamping @ 30 Amp 680 Volts 5 Clamping @ 100 Amp 1365 Volts

Main Rotor
SHAFT SHAFT
Connections

Diode Protection Device

For Transient Suppression

PRODUCT TRAINING
 Metal Oxide Varistor (Surge Suppressor)
DIODE PROTECTION DEVICE

Direction
of fault 5Typical high voltage transient created by
transient fault condition in the distribution system.
Up to 2- 3000V (peak voltage)

5 Energy absorbed
by Varistor. High Transient surges can be created by:-

5 ‘ Crash’ Synchronising onto live bus-bars.

5 Electric storm, (lightning), and field effects on
5 Varistor clamping
overhead lines (distribution systems).
level.
UC/BC 680V 5 Arcing, caused by faulty switching, motor
HC/F8 1365V failure, short circuits in the distribution system.

Full load D.C

t = µ sec's
output from Direction of D.C current to Main rotor
main Rectifier
duration.

PRODUCT TRAINING
 Excitation System - The Main Rotor

Main Rotor

Main Stator
Exciter
Rotor
& Stator

Bearing

Main Rotor
Main Rotor Shaft

Rectifier
Fan

PRODUCT TRAINING
 Main Rotor connections to Main Rectifier

Main Rectifier Main Rotor

SHAFT D.C

5 The Rectifier Output is a smooth D.C Supply across the Aluminium Heat Sinks
5 This is fed to the Main Rotor windings

PRODUCT TRAINING
 Main Rotor Winding - Coil Group connections

ANTICLOCK

D.C Input
From Main S
Rectifier

CLOCK CLOCK
N N

ANTICLOCK

5 The Rotor coils are connected in Series (4 Pole Rotor shown).

5 Each coil is reversed to the adjacent coil, producing the required polarity

PRODUCT TRAINING
 Wound Main Rotor - Poles & Frequency

Main Stator Coils in Slots (section) Main Stator Core

(section)
4 Pole Main Rotor

Air Gap

5 1 Cycle
S

N SHAFT N

5 Consider the Coils in the slot at 12 O'clock position, marked with the ARROW.

5 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

PRODUCT TRAINING
 Wound Main Rotor - Poles & Frequency

Main Stator Core

Main Stator Coils in Slots (section)
(section)
4 Pole Main Rotor

Air Gap
51 Cycle

S
SH
A
FT
S

N
5 The Rotor has now rotated Clockwise 45 º, until exactly half-way between
Negative and Positive Poles appears beneath the 12 O'clock position.

5 The coil conductors in this slot will now be at ZERO VOLTAGE.

PRODUCT TRAINING
 Wound Main Rotor - Poles & Frequency
Main Stator Core
Main Stator Coils in Slots (section)
(section)
4 Pole Main Rotor

Air Gap

N
51 Cycle

SHAFT

S
S

N
5 The Rotor has now rotated Clockwise 90 º, until the POSITIVE Pole is DIRECTLY
UNDERNEATH the 12 O'clock position.
5 The coil conductors in this slot will now be at the FULLY POSITIVE position
5 The 4 Poles will produce 2 FULL CYCLES for each 360 º FULL REVOLUTION.

PRODUCT TRAINING
 Wound Main Rotor - Poles & Frequency

2 Pole 4 Pole 6 Pole

S
S
N

N
SHAFT N SHAFT N SHAFT

S
S
N

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

60

PRODUCT TRAINING
 Wound Main Rotor - Poles & Frequency

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

60

FRQUENCY NUMBER SPEED

HZ (CYCLES) POLES (P) (N)

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

PRODUCT TRAINING
 Main Rotor- Amortisseur (Damper) Windings

5 Amortisseur Winding (Damper Bars)

S 5(Aluminium Damper Bars Welded to End Plates )

N SHAFT N

PRODUCT TRAINING
 Main Rotor- Amortisseur (Damper) Windings

N SHAFT N

5 Helps dampen speed oscillations resulting from cyclic irregularities in the

engine, (cause of ‘light flicker’).

5 Stabilises the mechanical systems during large load changes.

5 Stabilises load sharing with other Generators in Parallel.

5 Improves Harmonic Distortion in the Generator waveform

PRODUCT TRAINING
 Operation - Main Stator

Main Stator

Main Stator
Exciter
Rotor
& Stator

Bearing

Main Rotor
Main Rotor Shaft

Rectifier
Fan

PRODUCT TRAINING MAIN STATORS

 Wound Main Stator Assembly

5 Core built from high grade Electrical Steel, to reduce Iron losses (heat).
5 Each lamination is electrically insulated to minimise Eddy Currents in the core.
5 12 Ends Out Re-connectable, 6 Ends out Star / Delta, or Dedicated Windings.
5 Class ‘H’ Insulation as standard, 125 º C Temperature rise in 40ºC Ambient.
5 2/3rds Pitch windings, Triplen ( 3rd, 9th, ect.), Harmonics virtually eliminated.
5 HC,P7, & F8 range, all V.P.I Epoxy resin Impregnation as standard.
5 BC & UC range, trickle epoxy impregnation with epoxy or alkyde coating.

Laminated Steel core Copper Windings

Output Leads

PRODUCT TRAINING
 Wound Main Stator Assembly
Stator Winding Coils (Lap winding)
COIL PHASE GROUP
OUTPUT CONDUCTORS
OUTPUT
CONDUCTORS
COIL END
(OVERHANG)

STATOR COIL
CORE SPAN COIL
LENGTH (PITCH) TURNS

5 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.
5The Current capacity of the coil is determined by the copper conductors cross
sectional area, and number of conductors in parallel.

PRODUCT TRAINING
 Typical Main Stator 12 Wire Re-connectable
GROUP 1
FULL PITCH = 12 SLOTS
WINDING LEADS W1
START OF COIL V6 ( SPAN 1 - 13)
GROUP V2 W5
U6 2/3RDS PITCH = 2/3RD X 12
= 8 SLOTS
WINDING LEADS
U5
( SPAN 1 TO 9)

U1
FINISH OF COIL

U
2
GROUP COILS PER GROUP
= 48/12 = 4

S V1
W2
W6

V5
GROUP 3
N SHAFT N GROUP 4
V5

W6
S

W2
V1
U2

U5 U1
U6
W5 MAIN STATOR WINDING
MAIN ROTOR V2 SECTION ( 48 SLOT )
(4 POLE) W1 V6
GROUP 2

PRODUCT TRAINING WDG. PITCH

 Typical Main Stator 12 Wire Re-connectable

5 Connections shown in Series Star

W6
N U6V6 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

PRODUCT TRAINING
 Wound Main Stator 12 Wire Re-connectable
Series Star Parallel Star

U U
8
U1
U1 U5
U2
8
U5 U2 U6

U6
W2 V6
W6 N N V5
7 W1
W5
W2
V6 7
W1
V5
V2 W6
6 V1 V2 v
w v w W5 V1
6

Voltage Range (for winding 311) Voltage Range (for winding 311)
380 to 440 V @ 50 HZ 190 to 220 V @ 50 HZ
416 to 480 V @ 60 HZ 208 to 240 V @ 60 HZ
5 The stator windings are connected into six groups.
5 The groups can be connected by Newage, or the customer, to provide different voltage requirements.
5 Special Voltage requirements require special windings, e.g.; 600 Volt for Canada.

PRODUCT TRAINING
 Wound Main Stator 12 Wire Re-connectable

Series Delta Double Delta

U
8 6
Centre W6 U1
Tap W5 U2 V1 W6
V5 W2
W2 U5
W1 V2 W5
V6
W1 U6
6 7 8 7

U1 U2 U5 U6
V6 V5 V2 V1
w v U N w

Voltage Range (winding 311) Voltage Range (Winding 311)

220 to 250 V @ 50 HZ, 240 to 277 V @ 60 HZ 220 to 250 V @ 50 HZ, 240 to 277 V @ 60 HZ
No Neutral connection. Single Phase Only, output across U & W
Centre Tap for low volts (low current only) Centre Tap (N) for low volts
110 to 125 @ 50 HZ, 120 to 138 @ 60 HZ

PRODUCT TRAINING
 Wound Main Stator 6 Ends Out

Star connection
U
8
Voltage Range (winding 312) Number of Stator leads in parallel
380 to 440 V @ 50 HZ increases with current rating
U1
416 to 480 V @ 60 HZ of generator,
Single Phase (N) = L–L / √3 ie: 12, 18, 24, 36, or 48 leads out.
Dropper transformer required
for AVR sensing U2

N
W2 V2

W1 V1 7

w v
6

Each phase group is producing the full LINE to NEUTRAL voltage,

( Coil groups in each phase are in four parallel circuits).

The AVR cannot be connected directly to 6,7,and 8, for sensing signal or power

PRODUCT TRAINING
 Wound Main Stator 6 Ends Out
SENSING SUPPLY FOR A.V.R IN STAR CONNECTION
Star connection
U 8
Examples - 6 ends Stators
Winding 312
380 to 440 V @ 50 HZ
416 to 480 V @ 60 HZ U1
Single Phase (N) = L-L / √3
Isolation transformer
Winding 26
660 - 690 Volts @ 50 HZ
U2 8

N
W2 V2

W1 V1 7
7
W V

6 6

5 The AVR Sensing supply is connected to the main stator via a sensing
isolation transformer, which is fitted in the main terminal box.
5 Other windings producing higher voltage requirements will require a different
transformer ratio, to supply the AVR with the correct voltage adjustment range

PRODUCT TRAINING
 Main Stator Windings -Voltage Ranges
VOLTAGE LEVEL MUST BE WITHIN THE RANGE SPECIFIED FOR THE GENERATOR WINDINGS.

TYPICAL WINDING TYPES WITH VOLTAGE RANGES ( SERIES STAR)

Winding Number Stator 50HZ 60HZ

Number Phases Ends Min Mid Max Min Mid Max
311 3 12 380 415 440 416 460 480
312 3 6 380 415 440 416 460 480
25 3 12 660 675 690 - - -
26 3 6 660 675 690 - - -
13 3 6 - - - 380 400 416
14 3 12 - - - 380 400 416
17 3 12 - - 500 - - 600
7 3 6 - - 500 - - 600
5 1 4 220 230 240 - - -
6 1 4 - - - 220 230 240

5 BELOW MINIMUM LEVEL - POOR VOLTAGE RESPONSE TO LOAD CHANGES

5 ABOVE MAXIMUM LEVEL - EXCITATION CURRENT WILL BE TOO HIGH ON LOAD

PRODUCT TRAINING
 Operation of the Self Excited Generator

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

Bearing

Main Rotor
Main Rotor Shaft

Rectifier
Fan

PRODUCT TRAINING
 Operation of the Separately Excited Generator

5The Permanent Magnet Generator (PMG)

P2, P3, P4 Power Supply To A.V.R

5 Generator Shaft (Non-Drive -End)

5 Dowel Pin for PMG Rotor Location

5 Ceramic Magnet Rotor, highly magnetic saturated field. 8 Pole Rotor ,
100 HZ (at 1500 RPM ) or 120 HZ (at 1800 RPM )
5 Through Bolt fixture to Shaft non drive end
5 Permanent Magnet Stator 3 Phase A.C 170 to 220 Volts, separate power
supply for the A.V.R

PRODUCT TRAINING
 Operation of a Separately Excited Generators
P2 -P3 -P4

PMG
Power X+ (F1) A.V.R A.C Sensing
Supply 6-7-8 Supply From
To A.V.R XX- (F2) Main Stator
Main Stator (2 or 3 Phase)
Exciter
Rotor
& Stator

Bearing

Main Rotor
Main Rotor Shaft

Rectifier
Fan

5 THE PMG GENERATOR PROVIDES A SEPARATE POWER SUPPLY FOR AVR

PRODUCT TRAINING
 Operation of a Separately Excited Generators

ADVANTAGES OF SEPARATE EXCITATION SYSTEM

5 SUSTAINED SHORT CIRCUIT CURRENT UNDER FAULT CONDITIONS,

5 UNAFFECTED BY WAVEFORM DISTORTION CAUSED BY NON LINEAR LOADS

5 POWERFUL VOLTAGE BUILD UP SYSTEM ON INITIAL RUN-UP, DOES NOT RELY

UPON RESIDUAL MAGNETISM.

5 CAPABLE OF VOLTAGE BUILD UP AGAINST LOAD, (FREQUENCY STARTING OF

LARGE MOTORS).

5 ISOLATED POWER SUPPLY FOR THE AVR, (PROTECTS AVR FROM HIGH
TRANSIENT FAULT CONDITIONS IN THE DISTRIBUTION SYSTEM)

PRODUCT TRAINING
 P.M.G Assembly UC Frame sizes

Permanent
Magnet
Generator
Power
Supply
To A.V.R

5 THE PMG GENERATOR CAN BE RETRO - FITTED TO A SELF EXCITED GENERATOR

PRODUCT TRAINING
 PMG Rotor & Stator Assembly
HC & P7 Frames

Bearing Cap

P.M.G
Rotor
P.M.G
Stator

5 THE PMG IS FITTED AS STANDARD TO FRAME HC6 AND LARGER GENERATORS

PRODUCT TRAINING