Caterpillar Generator

®
®

Insulation Systems
Low Voltage Random Wound

Copper with Insulation

4 2 2 2
4 4 Resin/Varnish
4 2
4 4 2 2
4 2 Glass/Nomex/Stick
3 4 2 2
1
4 2
4 2 1 Slot Liner
1
3 4 1 3 2
1
3 3 4 3 1 Steel
1
3 3 1 1
3
3 3 1 1 1
3

4 4 2 2 2
4
4 2 2 2
4 4
4 2
4 2 2
3 1
4 2
4 2 1
1
4 3 2
3 1 1
3
3 4 3 1
3 1
3 3 1 1
3 1
3 3 1 1

Each number represents a multiple wire turn

in a four-turn coil.
Low Voltage Form Wound

Copper with Insulation

4 4 Resin/Varnish

3 3 Glass/Nomex/Stick

Polyester/Glass Tape
2 2
Slot Liner
1 1
Steel

4 4

3 3

2 2

1 1

Each number represents a multiple wire turn

in a four-turn coil.
Medium Voltage Form Wound

Copper with Insulation

4 4 Resin/Varnish

Mica/Polyester/Glass Tape
3 3
Glass/Nomex/Stick
2 2
Steel
1 1

4 4

3 3

2 2

1 1

Each number represents a multiple wire turn

in a four-turn coil.
High Voltage Form Wound

Copper with Insulation

Resin/Varnish
4 4
Mica/Polyester/Glass Tape
3 3

2 2 Conductive Tape

1 1 Semiconductive/Glass Armour Tape

Glass/Nomex/Stick

Steel
4 4

3 3

2 2

1 1

Each number represents a multiple wire turn

in a four-turn coil.
Random Wound Coils

Diamond Wound Concentric Wound

• Wound with round Class H copper magnet wire

insulated with a moisture resistant heavy polyester film
and amide imide overcoat
• Multiple conductors per turn
• Connections in phase groups
• Used in small kW size due to physical dimensions
• Used in clean, protected environments
Random Wound Stator Windings

Lap Wound Concentric Wound

• Used for machine winding

Form Wound Coils Form Wound Stator Winding
Before Impregnation

• Wound with Class H rectangular copper magnet wire
with coatings for exceptional dielectric capability
• Precision formed coils
• Each conductor and turn is positioned for better turn-
turn voltage, impulse and surge voltage, and harmonic
loads
• Taped coils (number of tape layers varies with voltage)
• Coils fit precisely into slots
• Symmetrical end turns
• Crimped and soldered lead connections
• Large spaces between coils:
— improves winding cooling
— reduces moisture retention
• Lacing, double surge ropes, and blocking of coil end
turns minimizes coil movement during surges
Random Wound Stator Form Wound Stator Windings
Windings

• Conductors are randomly placed within each coil and • Conductors are precisely placed within each coil and
group group
• Solid coil head • Coil head has open space for improved cooling
• Many irregular surfaces, crevices • Surfaces are smooth and well ventilated
• Coil head is braced with surge rope • Coil head is braced with double surge rope and
separators
• Main stator:
— impregnation with high quality dielectric varnish • Main stator:
— red sealer overcoating on main stator — Vacuum Pressure Impregnated (VPl) with resin
— red sealer overcoating on exciter stator (void-free)
— epoxy overcoat
— final red sealer coating
Four Pole Revolving Field (Rotor)

• Unipole lamination design

• Precision level wet wound (void-free)
• High bond strength epoxy
• Magnet wire with heavy polyester film and amide imide
overcoat, or heavy polyester film with amide imide
overcoat and fused double daglass wrap
• Overspeed:
— prototype tested at 125 percent rated speed for two
hours at 170 degrees Celsius
• Balanced in two planes at rated speed to 0.5 mils
maximum
• Amortisseur winging for damping oscillations and
reducing system overvoltages due to unbalance faults
Revolving Field End Turns

• Vented design for more efficient cooling

• High strength support bars
• Heavy epoxy coating gives high bond strength and
abrasion resistance
Random/Form Wound Generator Application Guide

STANDBY CONTINUOUS

CLEAN RANDOM RANDOM FORM LOW NONLINEAR

ENVIRONMENT WOUND WOUND WOUND LOAD

RANDOM RANDOM FORM

WOUND WOUND WOUND

HARSH FORM FORM FORM HIGH NONLINEAR

ENVIRONMENT WOUND WOUND WOUND LOAD

LOW POWER HIGH POWER

RATING RATING
LEGEND:
WINDING APPLICABLE AND RANDOM WINDING DECISION/REVIEW
TYPE WOUND
CAUTION TYPE
RECOMMENDED ALL FACTORS

Random Wound Form Wound

• Low power rating • High power rating
• Standby service (low operating hours) • Prime power service (continuous
• Clean protected environment operating hours)

• Low nonlinear loading • Dirty environment (moisture, salt,

chemicals, sand, abrasive dust)
• High nonlinear loading
Final Test

• Resistance test
• Hi-Pot (high potential) test
• High resistance test
• No load values at rated voltages
• Full load values at rated voltage
• Residual voltage
• Circulating currents
• Shaft currents (when applicable)
• Voltage balance
• Mechanical end play
• Phase rotation
• Full load generator test for ISO8528
 CAT, CATERPILLAR, their respective logos, and “Caterpillar Yellow,” as well as corporate
and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

LECX7076-01 © 2006 Caterpillar Inc. Printed in U.S.A.

All rights reserved.