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NEWAGE PRODUCT TRAINING NEWAGE PRODUCT TRAINING WHAT IS ELECTRICITY ? Electricity is a NATURAL form of ENERGY, e.g, LIGHTENING, STATIC CHARGE. ALL forms of MATTER in the Universe, (solid, liquid or gas), are made of ATOMS. The electrical force in the atom is called the ELECTRO-MAGNETIC FORCE. This force holds ELECTRONS in orbit, around the NUCLEUS of the ATOM. An electrical CHARGE, (or POTENTIAL DIFFERENCE),measured in VOLTS), is created when ELECTRONS are stripped from ATOMS. This CHARGE, (or VOLTAGE), provides the ‘pressure’ in an electrical circuit, causing ELECTRONS to flow in conductors. Lets take a closer look at the ATOM NEWAGE PRODUCT TRAINING WHAT IS ELECTRICITY ? - THE ATOM AA HYDROGEN COPPER ATOM ATOM NUCLEUS (POSITIVE CHARGE) ELECTRON (NEGATIVE CHARGE) VALENCE OR CONDUCTIVE BAND ELECTROMAGNETIC FORCE ELECTRON ‘SHELL’ 2 8 18 1 The ELECTRO MAGNETIC FORCE is second only in strength to the NUCLEAR FORCE. In a COPPER CONDUCTOR, the ELECTRON in the VALENCE band is FREE to flow from atom to atom, when attracted by a POTENTIAL DIFFERENCE or CHARGE. NEWAGE PRODUCT TRAINING WHAT IS ELECTRICITY? - VOLTAGE AND CURRENT A COPPER CONDUCTOR ATOMS 20 = 10 per cubic mm (100 BILLION BILLION) + ELECTRON FLOW IN A CONDUCTOR A POTENTIAL DIFFERENCE or CHARGE ,across a conductor, causes ELECTRONS to flow towards the positive charge, (electrons are negatively charged). The level of CHARGE is measured as VOLTAGE . CURRENT flow is possible because of ‘free’ electrons in the atoms from which the conductor is made. CURRENT flow can also be described in terms of electron flow. 1 Ampere flowing in a conductor at a given point in time would be equal to : 6 X 1018 electrons flowing / per second. NEWAGE PRODUCT TRAINING WHAT ARE CONDUCTORS CONDUCTORS IN A DOMESTIC CABLE CONDUCTORS IN A GENERATOR WINDING IRON CORE Conductors are materials where the atoms have free electrons which can flow from atom to atom, when induced by an electric charge (voltage). Most metals are good conductors, some of the best being silver, copper and gold. Good conductors have a very low resistance to current flow. Copper conductors are generally chosen for Generator windings because of its good electrical and thermal conductivity, relatively low cost, ease of use. NEWAGE PRODUCT TRAINING WHAT ARE INSULATORS INSULATION IN A DOMESTIC CABLE INSULATION IN A GENERATOR WINDING IRON CORE Insulators are materials where, the electrons are very tightly bound to the nucleus and to other atoms, (covalent bonding), hence there are no free electrons to carry an electrical charge. As a result, they are are a very poor conductors of electricity. Typically rubber,plastics, ceramics and glass are good insulators. They have a very HIGH resistance to current (electron) flow. The Voltage level, temperature rise, electrical, and mechanical properties, all determine the type of insulation materials chosen for a Generator winding. NEWAGE PRODUCT TRAINING WHAT IS D.C (DIRECT CURRENT) - + 12V D.C BATTERY Direct Current (DC) Voltage, can be produced by converting chemical energy directly into electrical energy. This is the BATTERY. A BATTERY is a storage device, i.e., the battery stores potential energy, which is known as the ‘charge’. The first battery was invented by VOLTA in 1800, and was called the VOLTAIC PILE. NEWAGE PRODUCT TRAINING COUNT ALESSANDRO GIUSEPPE ANTONIA VOLTA 1745 - 1827 VOLTAIC PILE COPPER & ZINC CELLS IN SALT WATER SOLUTION HE FOUND IT QUITE SHOCKING! In 1800,Volta invented the “VOLTAIC PILE”, which was the first BATTERY, and the first Electrical device to produce a continuous ELECTRICAL CHARGE. The VOLTAIC PILE was the fore- runner of the modern battery, with all its many varieties today. NEWAGE PRODUCT TRAINING A SIMPLE D.C CIRCUIT Electron flow Copper Conductor Switch + Light Bulb - + D.C BATTERY The battery creates a POTENTIAL DIFFERENCE or CHARGE across its terminals. We measure this charge as VOLTAGE. The battery acts like a ‘pump’, forcing electrons to flow around the circuit. When the switch is closed, the potential difference causes free electrons to flow through the conductors, and the light filament. The thin tungsten filament in the bulb acts as a ‘restriction’, or ‘resistance’, to the electron flow, heating the element and producing light. NEWAGE PRODUCT TRAINING WHY IS D.C USED IN AN A.C GENERATOR? A.C GENERATOR SET ALTERNATING D.C CONVERTED CURRENT FROM A.C A.C +V 0v V Anode Gate Silicon Controlled Rectifyer (Thyristor) Rectifier Diode Cathode All Generators produce Alternating Current (A.C). A D.C Generator is an A.C Generator, with its output converted into D.C by means of commutation, (reversal of the Negative cycle). In A.C Generators, D.C is produced by means of RECTIFICATION. D.C is used to produce the ELECTRO MAGNETIC FIELDS in A.C Generators. NEWAGE PRODUCT TRAINING WHAT IS A.C ( ALTERNATING CURRENT ) ? A.C Electricity (Alternating Current ), is produced by converting mechanical energy into electrical energy. This is the A.C Generator. The mechanical energy is provided by an Engine, or Turbine which drives the Generator. The Engine or Turbine may be powered by various forms of potential energy i.e. : Fossil fuels, (Petrol, Diesel, or Gas), or fuels from waste products (Methane). Steam from the heat produced by burning fossil fuels, or nuclear energy . Water Turbines, (Hydro Electricity), driven by the pressure of water from a river or Dam. Alternative energy produced by wind or wave turbines. NEWAGE PRODUCT TRAINING THE A.C GENERATOR PRIME MOVER (ENGINE OR TURBINE) A.C GENERATOR Mechanical power (HORSEPOWER) is converted into electrical power (KILOWATTS, or kW) by means of a prime mover (engine) driving the A.C Generator. NEWAGE PRODUCT TRAINING WHAT IS A.C POWER ? N REACTIV E (kVAr) S INDUCTIVE CIRCUIT LAGGING 90º CAPACITIVE CIRCUIT ACTIVE POWER ( kW ) ELECTRICAL POWER, (WATTS) in its simplest form = VOLTAGE X CURRENT A.C creates WASTED CURRENT in INDUCTIVE or CAPACITIVE circuits. The resultant APPARENT POWER , is called the kVA The POWER FACTOR, (COSINE of the phase angle ), is a measure of the WASTED or WATTLESS CURRENT component of the load. Generator output RATINGS usually give the full load kWATTS and kVA at 0.8 P.F. SO, HOW DOES AN A.C GENERATOR PRODUCE A.C POWER ? NEWAGE PRODUCT TRAINING CAN ANYONE GUESS WHAT THIS IS ? CAN ANYONE GUESS WHAT THESE ARE ? ZANUSSI CORRECT !! FRIDGE MAGNETS. BUT WHAT’S THAT GOT TO DO WITH A.C GENERATORS ? NEWAGE PRODUCT TRAINING MAGNETISM IN GENERATORS MAGNET N S MAGNETIC FLUX Magnetism is the essential force which produces the ELECTRO MOTIVE FORCE (EMF), in a Generator. Without MAGNETISM, you would have no fridge to stick your fridge magnets to !! NEWAGE PRODUCT TRAINING ELECTRO- MAGNETISM IN GENERATORS - + COPPER COIL (MAGNETIC FIELD) D.C BATTERY N CONVENTIONAL CURRENT FLOW (AMPERES) S MAGNETIC FLUX When a D.C supply is connected to a copper coil, current will flow in one direction through the coil, creating a magnetic field. If an iron core is placed into the magnetic field, it will become magnetized. The magnetic strength is determined by the D.C power (Voltage X Current) in the coil. This is the principle of ELECTRO-MAGNETISM, which is used to control the magnetic fields in an A.C Generators. NEWAGE PRODUCT TRAINING MICHEAL FARADAY 1791 - 1864 In 1831, Michael Faraday, using a simple magnet and a coil of wire,discovered that mechanical energy could be converted into electrical energy, NEWAGE PRODUCT TRAINING SIMPLE FARADAY GENERATOR ELECTRIC LIGHT BULB WATCH THE LIGHT BULB ! MAGNET COPPER COIL (CONDUCTOR) N S When the magnet is stationary, no work is being done, so no electricity is generated. When the magnet is moved rapidly passed the coil, work (energy) is being done, and this will generate the ELECTRO MOTIVE FORCE, (EMF or VOLTAGE), into the coil. NEWAGE PRODUCT TRAINING BASIC PRINCIPLES OF AN A.C GENERATOR Permanent Magnet Field Magnetic Field (Flux) N Shaft Copper loop +VE Slip-rings and Brushes S THIS TIME THE MAGNETS ARE STATIONARY, BUT THE COIL IS MOVING ! Output 0 -VE A.C Sinusoidal Output Voltage with A Permanent Magnet Field NEWAGE PRODUCT TRAINING BASIC PRINCIPLES OF AN A.C GENERATOR Magnetic Field (Flux) Electro- Magnetic Field ADJUSTABLE D.C SUPPLY Shaft Copper loop +VE Slip-rings and Brushes Output 0 -VE By controlling the D.C current into the magnetic field, the voltage level can be adjusted, allowing control of the output voltage. NEWAGE PRODUCT TRAINING SIMPLE A.C GENERATOR AIR GAP (MAGNETIC LINES OF FORCE OR FLUX) ELECTRO MAGNETIC FIELD D.C FIELD POLES A.C OUTPUT CARBON BRUSHE S SHAFT SLIPRINGS A.C ARMATURE WINDINGS ADJUSTABLE D.C SUPPLY The output Voltage is a product of (A), the strength of the magnetic field, (B), the length of conductors in the A.C armature (turns), and (C), the velocity (speed) of the conductors cutting the magnetic lines of force. NEWAGE PRODUCT TRAINING WHY DO WE CHOOSE A.C, AND NOT D.C ? Magnetic Lines of Force (Alternating flux) THE TRANSFORMER Laminated Steel Core Primary Winding (Input) Secondary Winding (Output) A.C can be increased or decreased by means of MUTUAL INDUCTION. This is achieved by the TRANSFORMER, and is essential for POWER DISTRIBUTION. SECONDARY VOLTAGE = RATIO OF PRIMARY TURNS : SECONDARY TURNS The A.C transformer enables us to distribute A.C POWER over very large distances. D.C cannot be transformed, and can only be distributed at the generated voltage. WHY IS THIS IMPORTANT ? NEWAGE PRODUCT TRAINING DISTRIBUTION OF A.C POWER MAINS SUPPLY A.C GENERATOR STEP UP TRANSFORMER SUPER HIGH TENSION CB 400,000V MCB STEP DOWN TRANSFORMER MCB A.C Voltage can be increased or decreased by transformers, By increasing the Voltage, overhead supply cables can be made much lighter. This allows load currents to be distributed over long distances at very high voltages. NEWAGE PRODUCT TRAINING TYPICAL ROTATING ARMATURE A.C GENERATOR MAGNETIC FLUX D.C FIELD POLES CARBON BRUSHES OUTPUT A.C A.C.ARMATURE SHAFT BEARINGS SLIPRINGS D.C INPUT Before the Late 1960’s, Newage A.C Generators were designed with a rotating A.C armature, from which the Generator output was taken. This was achieved by means SLIP-RINGS and carbon ‘ BRUSHES’ These had a tendency to wear out, spark, burn, and required regular maintenance. Newage switched to Brushless Generator design in the Late 1960’s. This became feasible following the invention of the Silicon Diode Rectifier NEWAGE PRODUCT TRAINING TYPICAL ROTATING D.C FIELD GENERATOR OUTPUT A.C CARBON BRUSHES A.C STATOR MAGNETIC FLUX SHAFT D.C SUPPLY D.C.FIELD (ROTOR) BEARINGS SLIPRINGS This generator has a rotating field (rotor), which is supplied with D.C via two slip-rings. The output is taken from the static A.C windings ( Stator), This design is still popular today, as the rotating field system is easier to design than a rotating armature, and more economical to manufacture. The main components of a Brushless Generator are of a similar design to above. However, Brushless Generators are designed without slip-rings and brushes. NOW LETS LOOK AT A BRUSHLESS GENERATOR NEWAGE PRODUCT TRAINING TYPICAL BRUSHLESS A.C GENERATOR RECTIFIER DIODES OUTPUT A.C MAGNETIC FLUX A.C STATOR SHAFT D.C.FIELD (ROTOR) EXCITER ROTOR EXCITER STATOR BEARINGS The SLIPRINGS and BRUSHES are now replaced with : The RECTIFYER ASSEMBLY which converts A.C VOLTAGE into D.C VOLTAGE. The EXCITER ROTOR, which provides A.C POWER to the RECTIFIER. The EXCITER STATOR, which is the ELECTRO-MAGNETIC FIELD for the EXCITER ROTOR. NOW LETS SEE HOW A BRUSHLESS GENERATOR WORKS NEWAGE PRODUCT TRAINING BRUSHLESS GENERATOR COMPONENT ASSEMBLY (TWO BEARING) Main Rotor Main Stator Exciter Rotor Exciter Stator Bearing Cartridge N.D.E Fan Bearing Cartridge D.E Key Shaft P.M.G Rotor P.M.G Stator Rectifier NEWAGE PRODUCT TRAINING BRUSHLESS GENERATOR COMPONENT ASSEMBLY (SINGLE BEARING) Main Rotor Main Stator Exciter Rotor Exciter Stator Fan Single bearing Coupling Bearing Cartridge N.D.E P.M.G Rotor P.M.G Stator Rectifier NEWAGE PRODUCT TRAINING Main Terminals A.V.R. on A.V.M,s Non drive end Bracket & Exciter Stator assy HC Generator Assembly Main Rotor Main Stator Fabricated Frame Drive end Bracket P.M.G Rotor P.M.G Stator NEWAGE PRODUCT TRAINING Air flow through Generator Air flow must not be restricted NEWAGE PRODUCT TRAINING NEWAGE PRODUCT TRAINING Excitation System Main Stator Exciter Rotor & Stator Bearing Main Rotor Shaft Rectifier Fan NEWAGE PRODUCT TRAINING Excitation System - Exciter Stator Exciter Stator Main Stator Exciter Rotor & Stator Bearing Main Rotor Shaft Rectifier Fan NEWAGE PRODUCT TRAINING Excitation System - Wound Exciter Stator X+ (F1) XX- (F2) To A.V.R Terminals COIL CONNECTIONS N S N S High-remanence steel core Stores Residual Magnetism 12-14 pole magnet field High frequency Generator NEWAGE PRODUCT TRAINING Excitation System - Exciter Rotor Exciter Rotor Main Stator Exciter Rotor & Stator Bearing Main Rotor Shaft Rectifier Fan NEWAGE PRODUCT TRAINING Excitation system - Exciter Rotor Assembly W U V SHAFT V U W 3 Phase A.C output, each Phase connected to 2 diodes on Main Rectifier. High Frequency output, ( from12 to 14 Pole Exciter Stator ). Exciter generator is a magnetic power amplifier for the main rotor current. NEWAGE PRODUCT TRAINING Excitation System - Exciter Rotor/ Main Rectifier Exciter Rotor and Main Rectifier Circuit Main Stator Exciter Rotor & Stator Bearing Main Rotor Shaft Rectifier Fan NEWAGE PRODUCT TRAINING Exciter Rotor and Rectifier Assembly Wound Exciter Rotor W U Rectifier Assembly V SHAFT SHAFT V U W Rectifier Assembly Mounted on Exciter rotor Core, (drive end side). NOTE: BC & Frame 8 Generators are mounted at the non-drive end side. NEWAGE PRODUCT TRAINING Exciter Rotor & Main Rectifier Assembly Exciter Rotor 3 Phase with Internal Star Point SHAFT NEWAGE PRODUCT TRAINING Exciter Rotor & Main Rectifier Connections Rectifier Input Terminal SHAFT SHAFT 3 Phase A.C Exciter Rotor Connected to Rectifier input terminals NEWAGE PRODUCT TRAINING Excitation System - The Main Rectifier Main Rectifier Main Stator Exciter Rotor & Stator Bearing Main Rotor Shaft Rectifier Fan NEWAGE PRODUCT TRAINING The Main Rectifier Assembly 3 Phase A.C Input from Exciter Rotor. (Insulated Terminals) Aluminium Heat-sinks Varistors (Surge Suppressors) Rectifier Hub Rectifier Diodes Negative Plate Anode Stud SHAFT Rectifier Diodes Positive Plate Cathode Stud Output to Main Rotor NEWAGE PRODUCT TRAINING Main Rectifier Assembly- Operation of a Diode +VE A.C Input to Rectifier Diodes Rectifier Diode Positive Heatsink Cathode Stud + 0 -VE +VE 0 -VE Rectifier Diode Negative Heatsink Anode Stud +VE 0 -VE for a 12 pole exciter field the frequency will be 150 or 180 HZ (cycles/second). NEWAGE PRODUCT TRAINING Main Rectifier Assembly- 3 Phase Rectification A.C Input to Rectifier Diodes D.C output to Main Rotor + Full wave 3 Phase rectification will produce a D.C output of 1.35 X A.C input voltage NEWAGE PRODUCT TRAINING Metal Oxide Varistor (Surge Suppressor) UC & BC Type 350 Volt Clamping @ 30 Amp 680 Volts HC & F8 Type 778 Volt Clamping @ 100 Amp 1365 Volts Diode Protection Device For Transient Suppression SHAFT Main Rotor Connections SHAFT NEWAGE PRODUCT TRAINING Metal Oxide Varistor (Surge Suppressor) DIODE PROTECTION DEVICE Direction of transient Energy absorbed by Varistor. Varistor clamping (Protection) level. Full load D.C output from main Rectifier t = µ sec's. Typical high voltage transient created by fault condition in the distribution system. Up to 2- 3000V (peak voltage) High Transient surges can be created by: ‘ Crash’ Synchronising onto live bus-bars. Electric storm, (lightning), and field effects on overhead lines (distribution systems). Arcing, caused by faulty switching, motor failure, short circuits in the distribution system. D.C supply to Main rotor NEWAGE PRODUCT TRAINING Excitation System - The Main Rotor Main Rotor Main Stator Exciter Rotor & Stator Bearing Main Rotor Shaft Rectifier Fan NEWAGE PRODUCT TRAINING Main Rectifier Connections to Main Rotor Main Rectifier Aluminium Heat-sinks SHAFT Main Rotor D.C The Rectifier Output is a smooth D.C Supply across the Aluminium Heat Sinks This is fed to the Main Rotor windings NEWAGE PRODUCT TRAINING Wound Main Rotor - Coil Group connections ANTI CLOCK D.C Input From Main Rectifier S CLOCK N N CLOCK S ANTI CLOCK The Rotor coils are connected in Series (4 Pole Rotor shown). Each coil is reversed to the adjacent coil, producing the required polarity NEWAGE PRODUCT TRAINING Wound Main Rotor - Poles & Frequency Generator Frequency (HZ) = Speed (N) X Pairs of poles (P) 60 6 Pole Available in Frame 7 4 Pole SHAFT N N N S 2 Pole SHAFT NEWAGE PRODUCT TRAINING Wound Main Rotor - Poles & Frequency Main Stator Core (section) Main Stator Coils in Slots (section) 4 Pole Main Rotor Air Gap N SHAFT N S 1 Cycle Consider the Coils in the slot at 12 O'clock position, marked with the ARROW. 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 NEWAGE PRODUCT TRAINING Wound Main Rotor - Poles & Frequency Main Stator Coils in Slots Main Stator Core 4 Pole Main Rotor Air Gap 1 Cycle The Rotor has now rotated Clockwise 45 º, until exactly half-way between Negative and Positive Poles appears beneath the 12 O'clock position. The coil conductors in this slot will now be at ZERO VOLTAGE. NEWAGE PRODUCT TRAINING Wound Main Rotor - Poles & Frequency Main Stator Core Main Stator Coils in Slots 4 Pole Main Rotor Air Gap S SHAFT S N 1 Cycle The Rotor has now rotated Clockwise 90 º, until the POSITIVE Pole is DIRECTLY UNDERNEATH the 12 O'clock position. The coil conductors in this slot will now be at the FULLY POSITIVE position The 4 Poles will produce 2 FULL CYCLES for each 360 º FULL REVOLUTION. NEWAGE PRODUCT TRAINING Wound Main Rotor - Poles & Frequency Generator Frequency (HZ or CYCLES) = Speed (N) X Pairs of poles (P) 60 FRQUENCY NUMBER ENGINE HZ (CYCLES) POLES (P) SPEED (N) 50 2 3000 50 4 1500 50 6 1000 60 2 3600 60 4 1800 60 6 1200 2 Pole 1 HZ = 60 RPM 4 Pole 1 HZ = 30 RPM 6 Pole 1 HZ = 20 RPM NEWAGE PRODUCT TRAINING Main Rotor- Amortisseur (Damper) Windings SHAFT Amortisseur Winding (Damper Bars) (Aluminium Damper Bars Welded to End Plates ) N N S NEWAGE PRODUCT TRAINING Main Rotor- Amortisseur (Damper) Windings Helps dampen speed oscillations resulting from cyclic irregularities in the engine, (cause of ‘light flicker’). Stabilises the mechanical systems during large load changes. Stabilises load sharing with other Generators in Parallel. Improves Harmonic Distortion in the Generator waveform NEWAGE PRODUCT TRAINING Operation - Main Stator Main Stator Main Stator Exciter Rotor & Stator Bearing Main Rotor Shaft Rectifier Fan NEWAGE PRODUCT TRAINING Wound Main Stator Assembly The Main stator insulation is class H as standard, allowing up to 165º C temperature. The laminated core is built from high grade Electrical Steel to minimise Iron losses. 12 Ends Out Re-connectable, or 6 Ends out Star / Delta, or Dedicated Windings. Windings are standard for most voltages, special windings required for some voltages Output Leads Laminated Steel core Copper Windings NEWAGE PRODUCT TRAINING Wound Main Stator Assembly Core length of Stator & Rotor (L) Determines KVA Rating for each Frame size,e.g. HC4 C, D ,E, F Core Lengths = 250 KVA to 400 KVA (@ 50 HZ) HC5 C, D, E, F Core Lengths = 450 KVA to 675 KVA (@ 50 HZ) HC6 G, H, J, K Core Lengths = 800 KVA to 1110 KVA (@ 50 HZ) HC7 E, F, G, H Core Lengths = 1350 KVA to 2000 KVA (@ 50 HZ) Core lengths L Output Leads Copper Windings Laminated Steel core NEWAGE PRODUCT TRAINING Wound Main Stator Assembly Stator Winding Coils (Lap winding) COIL PHASE GROUP OUTPUT CONDUCTORS OUTPUT CONDUCTORS COIL END (OVERHANG) STATOR CORE LENGTH COIL SPAN (PITCH) COIL TURNS 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. The Current capacity of the coil is determined by the conductor cross sectional area, and number of conductors in parallel. NEWAGE PRODUCT TRAINING Typical Main Stator 12 Wire Re-connectable 2/3RDS PITCH 8 SLOTS ( SPAN 1 TO 9) WINDING LEADS START OF COIL GROUP ONE PHASE GROUP ( 4 COILS PER GROUP) WINDING LEADS FINISH OF COIL GROUP FULL PITCH 12 SLOTS ( SPAN 1 - 13) MAIN ROTOR (4 POLE) SHAFT N N S MAIN STATOR WINDING SECTION ( 48 SLOT ) NEWAGE PRODUCT TRAINING Typical Main Stator 12 Wire Re-connectable Connections shown in Series Star N 6 AVR Sensing & Power supply 7 from Main Stator 8 W V6 Neutral W1 3 Phase Output V V1 U U1 NEWAGE PRODUCT TRAINING Wound Main Stator 12 Wire Re-connectable Parallel Star Series Star Voltage Range (winding 311) 380 to 440 V @ 50 HZ 416 to 480 V @ 60 HZ Voltage Range (winding 311) 190 to 220 V @ 50 HZ 208 to 240 V @ 60 HZ U U 8 U1 U2 W6 U5 U6 w U2 U6 N N W2 V6 V2 W2 W1 U5 8 V6 6 U1 V5 W1 W5 7 V5 V1 6 v w W6 V2 W5 V1 7 v The stator windings are connected into six groups. The groups can be connected by Newage, or the customer, to provide different voltage requirements. Special Voltage requirements require special windings, e.g.; 690 Volt for Co-Generation. NEWAGE PRODUCT TRAINING Wound Main Stator 12 Wire Re-connectable Series Delta Centre Tap 6 Double Delta 6 8 7 7 8 N Voltage Range (winding 311) 220 to 250 V @ 50 HZ, 240 to 277 V @ 60 HZ No Neutral connection. Centre Tap for low volts 1ph only Voltage Range (Winding 311) 220 to 250 V @ 50 HZ, 240 to 277 V @ 60 HZ Single Phase Only, output across U & W Centre Tap (N) for low volts 110 to 125 @ 50 HZ, 120 to 138 @ 60 HZ NEWAGE PRODUCT TRAINING Wound Main Stator 6 Ends Out Star U 8 Voltage Range (winding 312) 380 to 440 V @ 50 HZ, 416 to 480 V @ 60 HZ Single Phase (N) = 3 of Phase voltage Dropper transformer required for AVR sensing Number of Stator leads in parallel multiply’s with current rating of generator, ie: 12, 18, 24, 36, or 48 leads out. U1 U2 N W2 6 W1 w V2 7 V1 v Each phase group is producing the full line voltage, (all coil groups in each phase are in parallel). NEWAGE PRODUCT TRAINING AVR INPUT TERMINALS - SENSING SUPPLY Sensing Supply to A.V.R for 6 ends out STAR connected U Examples - 6 ends Stators Winding 312 380 to 440 V @ 50 HZ 416 to 480 V @ 60 HZ Single Phase (N) = 3 of L-L 8 U1 Isolation transformer U2 Winding 26 660 - 690 Volts @ 50 HZ 8 N W2 W1 V2 V1 7 v w 6 7 6 The AVR Sensing supply is connected to the main stator via a sensing isolation transformer, which is fitted in the main terminal box. Other windings producing higher voltage requirements will require a different transformer ratio, to supply the AVR with the correct voltage adjustment range NEWAGE PRODUCT TRAINING Excitation Control - Automatic Voltage Regulator (A.V.R) The A.V.R A.V.R Main Stator Exciter Rotor & Stator Bearing Main Rotor Shaft Rectifier Fan NEWAGE PRODUCT TRAINING Excitation System - Self Excited Generators X+ (F1) D.C Output From A.V.R Into Exciter Stator XX- (F2) A.C Power & Feedback Signal (Sensing) From Main Stator A.V.R Main Stator Exciter Rotor & Stator Bearing Main Rotor Shaft Rectifier Fan NEWAGE PRODUCT TRAINING Automatic Voltage Regulator (AVR) Type SX460/2 (Self -Excited) VOLTS X XX 6 7 8 1 2 3 4 WARNING! ELECTRIC SHOCK [Live Terminals] UFRO 50HZ C 60HZ STABILITY NEWAGE PRODUCT TRAINING Automatic Voltage Regulator (AVR) Type SX440 (Self Excited) 3 2 2 1 TRIM WARNING! ELECTRIC SHOCK [Live Terminals] DROOP VOLTS UFRO 50 C 60 STABILITY Input Var/ PFC3 Input Droop C/T 8 7 6 5 4 3 2 1 X S2 S1 A2 A1 P4 XX 8 7 6 5 4 3 2 1 K2 K1 P2 P3 Linking for 3 Phase Sensing Unit C B A NEWAGE PRODUCT TRAINING Automatic Voltage Regulator (AVR) Type MX341 P/N E000-23412/1P 3 2 2 1 TRIM WARNING! ELECTRIC SHOCK [Live Terminals] MX341-2 E000-23412 DROOP VOLTS 8 7 6 5 4 3 2 1 X S2 S1 A2 A1 P4 XX 8 7 6 5 4 3 2 1 K2 K1 P2 P3 Linking for 3 Phase Sensing Unit EXC TRIP DIP STABILITY UFRO 3 1 2 C B A NEWAGE PRODUCT TRAINING Automatic Voltage Regulator (AVR) Type MX321 P/N E000 -23212 P4 K2 K1 P2 P3 XX X 6 P4 7 8 1 2 VOLTS RAMP I /LIMIT FREQUECY SELECTION UFRO 3 2 1 DIP R.M.S DWELL STABILITY STABILITY SELECTION U OVER/VOLT EXC TRIP E0 E1 B0 B1 C V W DROOP TRIM S1 S2 S1 S2 S1 S2 A1 A2 B A NEWAGE PRODUCT TRAINING Operation of AVR - as an electronic switch DIODE CIRCUIT SILICON CONTROLLED RECTIFIER (SCR) Gate A.C Power Supply AVR Control Circuit A.C Power Supply X 1/2 Wave D.C 1/2 Wave D.C Exciter field Exciter field A DIODE will conduct continuously, producing half wave rectification of the A.C supply. A DIODE, however, would not CONTROL the D.C into the exciter field, which is necessary to control the Generator voltage. A SILICON CONTROLLED RECTIFIER (SCR or THYRISTOR) is a diode with a control GATE. The SCR will only switch ON when the GATE receives a signal from the AVR controls. NEWAGE PRODUCT TRAINING Operation of AVR - as an electronic switch D.C Pulses From A.V.R Into Exciter Stator X+ (F1) A.V.R A.C power supply from Main Stator Sensing Supply (2 or 3 phase) XX- (F2) Exciter Rotor & Stator Bearing Main Rotor Shaft Rectifier Fan The AVR switches the D.C power supply ON and OFF 50 - 60 times per second. For PMG powered AVR,s 100 - 120 times per second. NEWAGE PRODUCT TRAINING Operation of AVR - as an electronic switch Phase Control of AVR power supply (Self Excited) AC power supply to AVR 170 to 240V. 50 or 60 HZ . D.C Power supply (1/2 cycle rectification) Power ON After time (T) OFF OFF Number of pulses are the same as the A.C power supply frequency (50 or 60/second) NO LOAD D.C Pulses into the Exciter Stator X+(F1) XX-(F2) (T) The power device (Thyristor or SCR) is switched ON by the control circuit, after time delay (T). The Thyristor automatically switches OFF as the power supply pulse falls to zero after each cycle. NEWAGE PRODUCT TRAINING Operation of AVR - as an electronic switch Phase Control of AVR power supply (Self Excited) Power ON After time (T) OF F OF F (T) FULL LOAD D.C Pulses into the Exciter Stator X+(F1) XX-(F2) As LOAD is increased , the time delay (T), will automatically decrease. The larger the pulse area (in RED) the higher the D.C power into the exciter stator.. . The AVR will stabilise at the new output level , when the sensing signal into the AVR has returned to normal (nominal) voltage, as pre-set on the ‘VOLTS’ adjustment. NEWAGE PRODUCT TRAINING Operation of AVR - as an electronic switch Phase Control of AVR power supply (Self Excited) Power ON After time (T) OFF OFF (T) OVERLOAD D.C Pulses into the Exciter Stator X+(F1) XX-(F2) Although the red pulses are now termed ‘OVERLOAD’, the AVR requires this additional power to provide a rapid response to transient load application, ( to reduce voltage DIP). This short term response demands ALL of the power supply available for approximately 0.3 seconds, until the output voltage has returned to normal. NEWAGE PRODUCT TRAINING Excitation System - Separately Excited Generators The Permanent Magnet Generator (PMG) P2, P3, P4 Power Supply To A.V.R Generator Shaft (Non-Drive -End) Dowel Pin for PMG Rotor Location Ceramic Magnet Rotor, highly magnetic saturated field. 8 Pole Rotor , 100 HZ (at 1500 RPM ) or 120 HZ (at 1800 RPM ) Through Bolt fixture to Shaft non drive end Permanent Magnet Stator 3 Phase A.C 170 to 220 Volts, separate power supply for the A.V.R NEWAGE PRODUCT TRAINING P.M.G Assembly UC Frame sizes NEWAGE PRODUCT TRAINING PMG Rotor & Stator Assembly - HC Frames Optional on HC4,& HC5 3 Phase A.C, 170- 220 Volts P.M.G Rotor P.M.G Stator in Housing NEWAGE PRODUCT TRAINING Excitation System - Separately Excited Generators PMG Power Supply To A.V.R P2 -P3 -P4 X+ (F1) A.V.R A.C Feedback Signal only. (Sensing) from Stator 6-7-8 XX- (F2) Main Stator Exciter Rotor & Stator Bearing Main Rotor Shaft Rectifier Fan NEWAGE PRODUCT TRAINING Excitation System - Separately Excited Generators Advantages of the PMG System The PMG is a separate power supply for AVR, which is unaffected by adverse loading conditions such as :Waveform distortion caused by non linear loads Transient fault conditions in the distribution system. Provides a powerful voltage build up system on initial runup, (does not rely upon residual magnetism) Provides sustained short circuit current under fault conditions, (requirement for all Marine classifications). NEWAGE PRODUCT TRAINING NEWAGE PRODUCT TRAINING