Medium & High

Voltage Generators

PRODUCT TRAINING
PRODUCT TRAINING
PRODUCT TRAINING
PRODUCT TRAINING
 Medium Voltage MV7 Basic Construction
Main Rotor Wire Wound MV
Non drive Stator Assembly
end Bracket Drive end
Fabricated Bracket
& Exciter Frame
Stator assy

Bearing Cap

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

 The mechanical construction of a MV7/HV7 frame is similar to a low Voltage machine.

 The main differences are in the output (main stator) windings, and output connections

PRODUCT TRAINING
 Medium Voltage MV7 Terminal Box Construction

AVR on Sensing Transformer Star Point

Antivibration For A.V.R Neutral connection
Mounts

V2
U2
W2
3.3kV/240
TRANSX

U V W N

Customer C/T’s 3 Phase

Output terminals

PRODUCT TRAINING
 Medium Voltage MV7 Wound Main Stator
 laminated core is built from low loss Silicon Steel, to reduce Iron losses (heat).
 Each lamination is electrically insulated to minimise Eddy Currents (iron losses).
 Class ‘F’ Insulation with Mica/Nomex composite slot liner combination.
 Multiple coated round conductors,with Enamel and glass tape insulation.
 Fully taped end-Windings with surge rope for mechanical strength .
 6 Ends out Stator leads, Neutrals brought out for customer CT connections.
 2/3rds pitch windings, Triple Harmonics, ( 3rd, 6th, 9th ect.) virtually eliminated.
 V.P.I Epoxy resin Impregnation, with rotary curing to prevent resin run-off.

Flexible cable
Output Leads Low loss Silicon MV Winding
Steel Laminated core supplied with
R.T.D’s

PRODUCT TRAINING
 Medium Voltage MV7 Winding - up to 4160 V
Winding Slot cross section - Insulation materials

Slot Wedge
Epoxy glass laminate
Top shoe
Nomex/Polyester/Nomex
TOP box Slot Liners
Hypotherm F/PS Nomex/Polyester/Nomex

Felt Packer
Coil Separator
Resin retainer
Polyester Glass laminate

Copper Conductors
Lower Coil Separator
VPI Impregnation Nomex/Melinex/Nomex

IRON
CORE

PRODUCT TRAINING
 P80 - Medium(MV) & High(HV) Voltage Generator
Auxiliary Terminal
Terminal Box Box Assy
Access Panel
U Form Wound
V Main Stator
W Winding
N
6.6kV/240 Cable
Saddle TRANSX
Entry
Glandplate
Permanent
Magnet Drive end
Generator Bracket
Frame  Main frame bars.
Drive end
Covers  Welded to core pack Bearing
Screen Support
Air
Inlet  Main Stator core
Cover

Bearing
Cap Main Rotor
Assembly

Non Drive end

Bracket & Exciter
Stator assembly Feet

PRODUCT TRAINING
 P80 MV & HV Main Terminal Box Construction
Auxiliary Sensing (Signal) Customer CT’s Star Point
terminal Transformer for AVR. (up to 9 allowed for). Neutral connection
Box

U V W N
6.6kV/240
TRANSX

3 Phase Cable carrier

Output terminals

PRODUCT TRAINING
 P80 MV & HV Auxiliary Terminal Box
Automatic Voltage Anti-Vibration Output Connections
Regulator (AVR) mounted Chassis CT’s, RTD’s, Accessory Units
MA330

Automatic Voltage Regulator MA330

1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8
COVER P/N = E00-13305A
Automatic Voltage Regulator MA330

Part No. E000-13300

Part No. E000-13300

MA330
12/04

AVR
076-05214
11/01

954623
ISSUE-1

INTERNATIONAL
076-05213

NEWAGE
W 2115

WO6G

8
Ltd
K1
B1
Over Over K2
B0 Volts Exc
P2
E3
P3
E4
P4

S2
S1
F2
0V
A2 F1
A1
0V 47nk 63
8
2

1
6 5 4 7
3 RMV 7
2 8 Mode Maxim 6
0V
9 0 1 mx536aj

47nk 63
0V
AOR
Pwl
TRP

47nk 63
+14V
Hand

Dip Droop Selection Selection Volts

Ramp Dwell Trim Ufro Stab
Ufro Stab
6 5 4 6 5 4
3 7 3 7
2 8 2 8
9 0 1 9 0 1

Power Factor Correction

Module (PFC3)

 The Control system is totally Isolated from the High Voltage components

PRODUCT TRAINING
 P80 Medium & High Voltage Main Stator
 laminated core is built from low loss Silicon Steel, to reduce Iron losses (heat).
 Each lamination is electrically insulated to minimise Iron losses (Eddy Currents).
 Class ‘F’ Insulation with Mica/Nomex composite slot liner combination.
 Form wound diamond coils, Mica taped, HV windings are fitted with corona shield.
 Hybrid impregnation,Resin rich in slots, Global VPI Epoxy impregnation to end windings.
 Fully taped end-Windings with surge rope, bracing & blocking for mechanical strength.
 6 Ends out Stator leads, Neutrals brought out for customer CT connections.
 2/3rds Pitch windings, Triplen ( 3rd, 9th, ect.), Harmonics virtually eliminated.
 V.P.I Epoxy resin Impregnation with rotary curing to prevent resin run-off.

Flexible HV
cable Output
Leads MV & HV
Form Wound coils
Low loss Silicon
R.T.D’s fitted as
Steel Laminated core
standard

PRODUCT TRAINING
 Frame 8 Medium & High Voltage Main Stator Winding

Top Wedge
Packing

Conductors, with
Enamel Glass
taping insulation
Separator, with
Graphite tape
(HV only)
Main Wall insulation
IRON
CORE Strip of Conductive
Conductive Graphite
covering( HV only) Graphite tape at
bottom of slot
(HV only)

PRODUCT TRAINING
 Frame 8 MV & HV Form Wound Main Stator Coil
End of
stator slot
Conductor insulation

Endwinding Slot section

Endwinding
cover tape Conductors

Graphite loaded semi-conductive

stress control tape (HV only)
Main Wall insulation
Conductive graphite
tape(HV only)

PRODUCT TRAINING
 MV & HV Generators - Special Requirements
Environmental Protection

 Medium and High voltage Windings must be protected from humidity and
condensation, or when stationary for long periods (stand-by duty).
 Anti-condensation Heaters must be switched on when stationary, to drive off
condensation and prevent absorbency of moisture.
 Air filtration is required for dusty environments, where build up of dirt on the
winding could cause static discharge, with possible damage to the winding
insulation system.
 Never run an MV or HV generator which has been subjected to ingress of water or
other contaminant without first carrying out an insulation check.
 Specialised techniques must be employed to :-
a) Test the winding insulation, and
b) Clean and/or dry out a winding which has become contaminated.
 NOTE: To avoid possible Insulation damage , the Insulation Resistance must first
be checked with a maximum test voltage of 500V , before higher voltages are
applied to the windings, ( especially if wet, or contaminated ).

PRODUCT TRAINING
 MV & HV Generators - Special Requirements

SAFETY NOTICE

DANGER!
ELECTRIC SHOCK
[Live Terminals]

 Medium and High voltage windings can hold a STORED CAPACITIVE CHARGE long
after the Generator set has been stopped .
 Do not attempt any work on or near the Generator terminals without grounding the
Main Stator windings to earth.
 After high voltage tests have been performed, the windings must be grounded for at
least 15 minutes, to avoid any dangerous potential build up.
 The following tests should only be carried out by qualified and/or experienced
engineers who have received SAFETY TRAINING ON HIGH VOLTAGE EQUIPMENT.
 All test instruments and their leads/connectors/ probes must be checked to ensure
that they are suitable for the voltage levels being tested, and are in good working
order.
 Ensure that the work area is SAFE, other personnel in the area are advised of what
you are doing, warning notices and tapes are displayed to advise others of the
hazards.

PRODUCT TRAINING
 MV, & HV Windings - Polarisation Index Testing

Polarisation Index (PI), is a method of testing the cleanliness and dryness of a Medium or High
Voltage winding.
 The test is carried out with a 2500, or 5000 Volt motorised Insulation tester :-
 2500V for Medium voltage windings up to 4.5kV.
 5000V for High voltage windings up to 13.8kV.
The P.I tester is connected across phase and earth, with the other two phases strapped to earth.
 The Neutral star point connections must be separated, (open circuit).
 An insulation reading is taken after 1 minute, then a further reading taken after 10 minutes.
 Polarisation Index (P.I) = IR after 10 minutes
IR after 1 minute.
 MINIMUM P.I INDEX VALUE SHOULD = 2.0, OR HIGHER AT 20º C.
A value of less than 2.0 suggests the windings are dirty or wet, and must therefore be cleaned
and/or dried out before running at full voltage.
MINIMUM INSULATION VALUE TO GROUND AFTER 1 MINUTE =
Medium Voltage = 100 Megohms, High Voltage = 300 Megohms

 NOTE: Disconnect the AVR sensing transformer before carrying out IR tests.

PRODUCT TRAINING
 MV & HV Windings - Polarisation Index Testing
Open
Circuit
Neutral
N

W2

V2
U2
3.3kV/240
TRANSX

U V W

1 MINUTE

MEGGER BM25
MOTORISED
M G MEGGER
100 1G 10
1 10 10
0. 1 0
EARTH
1T

PI = 2.84 AFTER 1 MINUTE

PRODUCT TRAINING
 MV & HV Windings - Polarisation Index Testing
Open
Circuit
Neutral
N

W2

V2
U2
3.3kV/240
TRANSX

U V W

10
1 MINUTES
MINUTE

MEGGER BM25

M G Motorised
100 1G 10
0. 1
1 10 10
0 Megger
EARTH
11TT

PI
PIPITEST
==8.44RESULT
2.84AFTER
AFTER =1 8.44
10 / 2.84
MINUTES
MINUTE
= 2.97
PRODUCT TRAINING
 MV & HV Windings - Cleaning and Drying Windings

 If the winding PI is less than 1.5, or the Insulation resistance (IR) to earth is less
than MINIMUM VALUE , the windings will require treatment.
. The windings must firstly be checked for moisture, especially If the generator
has been stationary, without anti-condensation heating for a long period.
 There are two recommended methods for drying out the windings :-
 a) SHORT CIRCUIT STATOR METHOD
For removing moisture without dismantling the generator
 b) OVEN DRYING
For drying out the stator windings after dismantling and cleaning processes.
 Both processes are required to achieve a PI index higher than 1.5, and an
Insulation Resistance higher than minimum value.
 MINIMUM INSULATION VALUE TO GROUND = kVolt rating of Generator, (in
Megohms), plus 1 Megohm.

PRODUCT TRAINING
 MV & HV Windings - Short Circuit Drying of Windings

V2
U2
W2
3.3kV/240
TRANSX

U V W

Clampmeter
Short Circuit Links

S
RM
MAKE SURE THAT THE AVR IS DISCONNECTED!

UE
TR
 Attach SHORT CIRCUIT link to all 3 phases (NOTE: Shorting Links must be
capable of carrying the full load current)..
 The short circuit current must be monitored at all times, using the instrument
C/T’s on the Neutral bus-bar, or a clamp meter.

PRODUCT TRAINING
 MV & HV Generators - Oven Drying the Windings
Fan assisted drying oven

 The Windings Temperature should be increased slowly (5- 6ºC per hour) up to a
maximum temperature of 90ºC. The Stator R.T.D resistance can be used to measure
the internal temperature of the windings. ( see next slide).
 The drying process should be maintained at up to 90ºC for a minimum of 20
hours , until a minimum P.I of 1.5, and IR above MINIMUM VALUE, is achieved

PRODUCT TRAINING
 RETURN TO MAIN MENU

PRODUCT TRAINING