CHAPTER 3.

ALTERNATOR

1. DESCRIPTION
These instructions refer to three-phase synchronous generator (alternator), and so on. Technical data and constructive
details are given in the catalogue.
The alternators are synchronous, brushless type, self excited and self regulated, manufactured according to the
standards IEC 34-1.

2. COMMISSIONING

2.1. INSULATION TEST

If the alternator has been kept in storage for a long period of time, it is a good practice to test the stator windings for
ground insulation before starting up.
Before doing this test, it is necessary to disconnect the voltage control system (AVR or similar devices) & all lead
wire(U,V,W,N).

The insulation resistance of windings to earth should be measured using a suitable DC instrument (“"Megger”"
instrument or a similar one), which output voltage (test voltage) is equal to 500 V for low voltage generators and not
less than 1000 V for medium voltage generators.
Reading of insulation resistance will be done after having applied Megger output for 1 minute to winding.
For a new generator, the stator winding insulation resistance larger of 100MΩ represent one of essential safety
requirements.

▶ Do not touch power terminals during and immediately after the insulation resistance check because the
winding is in voltage.

- 19-
2.2. BALANCING

Unless otherwise indicated the rotor is balanced dynamically with a half-key fitted on the shaft extension, in
compliance with IEC 34-14.

2.3. INSTALLATION CONDITION s

Install the alternator in a ventilated room. If installed in closed areas the alternators should have a possibility to
exchange the cooling air directly with atmosphere. Air outlet and inlet openings should not be obstructed: provisions
should be taken to prevent obstacles from obstructing ventilation openings. The inlet of warm air should be avoided.

3. CONNECTION & AVR

3.1 GROUNDING

▶ Inside the terminal box there is no terminal for grounding, but neutral phase could be used as terminal for

grounding. Grounding has to be carried out using a copper wire of suitable size, in compliance with applicable
standards.
The number of lead is different depending on model of alternator. Terminal arrangement permits star(Y) or

- 20-
parallel star(YY) connection, according to following diagrams.

3.2 WIRING DIAGRAMS FOR STANDARD ALTERNATOR

3.2.1. 12 leads, 8 terminals on terminal board - star(Y) connection

50Hz : 380Vac ~ 420Vac (L – L), 220Vac ~ 240Vac (L – N)

60Hz : 380Vac ~ 480Vac (L – L), 220Vac ~ 277Vac (L – N)

Figure 3-1. 12 leads, 8 terminals on terminal board - star(Y) connection

3.2.2. 12 leads, 8 terminals on terminal board – star parallel(YY) connection

50Hz : 190Vac ~ 210Vac (L – L), 110Vac ~ 120Vac (L – N)

60Hz : 220Vac ~ 250Vac (L – L), 127Vac ~ 145Vac (L – N)

- 21-
 Figure 3-2. 12 leads, 8 terminals on terminal board - star parallel(YY) connection

3.2.3. 12 leads, 8 terminals on terminal board – zigzag connection (1 PHASE)

50Hz : 220Vac ~ 240Vac (L – L), 220Vac ~ 254Vac (L – M)

60Hz : 220Vac ~ 250Vac (L – L), 127Vac ~ 145Vac (L – M)

3.2.4. 12 leads, 8 terminals on terminal board – double delta connection (1 PHASE)

Figure 3-3. 12 leads, 8 terminals on terminal board – zigzag connection (1 PHASE)

50Hz : 220Vac ~ 240Vac (L – L), 220Vac ~ 254Vac (L – M)
60Hz : 220Vac ~ 250Vac (L – L), 127Vac ~ 145Vac (L – M)

- 22-
 Figure 3-4. 12 leads, 8 terminals on terminal board – double delta connection (1 PHASE)

The output cables have to be fixed to the terminal board as indicated in the following figure.

Figure 3-5. connection terminals on terminal board

3.3. VOLTAGE REGULATOR

The alternators are provided with automatic voltage regulator (AVR).

The AVR is provided with potentiometers to adapt the characteristics of the AVR to the different operating conditions.
The AVR is provided with adjustable stability circuitry to allow operations in a wide range of applications.
The AVR is equipped also with protecting circuit allowing the alternator to operate under speed if not loaded.

▶ It is not advisable to have the alternator operating loaded when the frequency (speed) is below the rated
value: this kind of operation is an overload for the whole excitation system of the alternator.

- 23-
3.3.1. AVR application

MAVC6307F, UVR6, DER-1, SR7

3.3.2. Fuse

▶ On the AVR there is a protecting fuse. In case it should be necessary to replace it, high speed fuses should be
used; in addition they should have high breaking resistance.

3.3.3. Connection of MAVC6307F

The AVR is connected to the terminals of the alternator and to exciter using terminals.
Short terminals 50 and COM together for 50Hz operation. Leave unconnected for 60Hz operation.

Figure 3-6. AVR MAVC6307F connection diagram(E-SERIES)

- 24-
 Figure 3-7. backplate of MAVC6307F

Figure 3-8. DSR connection diagram (C-SERIES)

- 25-
 Figure 3-9. SR7 connection diagram (C-SERIES)

Figure 3-10. UVR6 connection diagram (C-SERIES)

- 26-
3.3.3. Use of potentiometers

VOLT - potentiometer for adjusting the output voltage of the generator.

It allows a wide range of voltage setting. In case of resetting this potentiometer the voltage has to be set within 10% of
the rated voltage of the machine.
In order to obtain a finer regulation, or to adjust the voltage from control panel or to limit the voltage range, it is
possible to insert an external potentiometer.

⇒ increase voltage ⇒decrease voltage

STAB - potentiometer for stability adjust

⇒increase response time, decrease stability. ⇒ decrease response time, increase stability.

Rheostat for remote voltage setting

For all alternators, that rheostat can be inserted between the auxiliary terminals VR1 and VR2 of the AVR. If rheostat
is not used, the terminal of VR1 and VR2 should be common. The external rheostat has to be inserted with its wiper in
intermediate position and then the internal potentiometer of AVR (VOLT) has to be reset to obtain the nominal
voltage.
Recommended resistance of rheostat : 2kOhm

- 27-
4. REPAIRING

4.1 SAFETY PRECAUTIONS

▶ Repair or fault correction must be performed according to the instruction to avoid accident occurring. Also,
the original status must be kept.

▶ All works on the generators must be carried out by trained and qualified personnel in the electronic and
mechanic field as well as operation, repair and maintenance.
Any work about the generator cannot be performed only with a manual or an automatic system. Therefore,
you should know how the generator works.

4.2 GENERAL MAINTERNCE

4.2.1 Inspection after Starting

After the generator operates for 20 hours, check all locking bolts for tightening, internal status of the generator and all
wires relating with the installation for normal operation.

- 28-
4.2.2 Bearings

The bearing is lubricated permanently: approximate life of the lubricant (depending on the use) =20000 hours or 3
years.
Check the temperature rise in the bearing. The temperature in the bearing should not be 60°C higher than ambient
temperature. If it is, the generator must stop to check.

4.2.3 Maintenance for Electrical parts

Winding product must be kept clean.

▶ Do not use trichloroethylene, perchlorethylene, methyl chloroform or any product of strong basicity.

It is allowed to use strictly approved purely volatile degreasing product, such as:
- Ordinary gasoline (free of additive),
- Toulon (poisonous slightly), flammable,
- Benzene (or naphtha, poisonous), flammable, and
- Cyclohexane (nontoxic), flammable.

▶ Clean stator, rotor, exciter and diode rectifier.

Insulation structure and infiltration system should not be damaged by solvent (see above “authorized”
products).

▶ Avoid cleaning thing to flow into the trough. For the products with brush, it should be wiped with sponge

usually to avoid accumulation on the casing. Use dry cloth to dry the winding.

- 29-
4.2.4 Maintenance for Mechanical parts

Do not use water or high pressure rinsing to clean the generator, or our product guarantee will be invalid for any
resulted problems.
Degreasing: use a brush and cleanser to do it (applicable for paint)
Dirt removal: use an air gun to do it.
If the filter is installed without heat protection equipment when making generator, maintainer should clean air filter
regularly and periodically (daily cleaning is necessary in dusty environment).
Use water to clean dry dust. In the dusty greasily environment, use bathing soap or cleanser for cleaning.
Gasoline or chloroethylene can be used.
After the generator is cleaned, it is necessary to check the insulation of the winding.

4.3 FAULTS INSPECTION

If the generator cannot operate normally when you work, the cause of the fault must be found. In order to do it, check:
- Protection equipment for correct installation.
- Connection for consistency with connection drawing in the operation manual.
- Setting for correct speed (see nameplate).

- 30-
 4.4 MECHANIC FAULTS

Fault Action
Bearing One or two bearings - If the color of bearing changes into blue or the color of
overheating(the temperature of lubricant changes into black, replace bearing.
the bearing is over than 80°C). - The end cover is not aligned (flange is not installed
There is abnormal noise or not. correctly).

Abnormal The base of the generator - Air route (inlet and outlet) blocked or the hot air of prime
Temperature overheating (the temperature of mover and generator circulated repeatedly. Remove the
it is 40°C higher than ambient blockage in the air route.
temperature). - The operation temperature of the generator is too high (when
loaded, the voltage is 105% higher than rating voltage)
- The generator is over loading.

Fault Phenomenon Cause Solution

Vibration Heavy vibration - Not aligned (coupler).
- Installation or the combination with prime mover is not
qualified.
- The rotor balance is not qualified (prime mover - generator)
There is obvious noise in the - The generator operates with single phase (single phase
generator and obvious vibration. loaded or wrong switch or installation)
- The stator is short circuit.
Noise The generator is bumped - The system is short circuit.
obviously with subsequent noise - Parallel operation is wrong.
and vibration. Possible results:
- The coupler is broken or damaged.
- Shaft end is broken or damaged.
- Rotor is distorted or short circuit.
- There is crack on the fan or the fan is not tightened on the
shaft.
- There is irreparable damage on the rotating diode or AVR.

- 31-
1.Electricity cannot be 1）Fuse is broken 1）After confirming circuit is normal,
produced or the
voltage is abnormal 2）Ammeter is damaged replace fuse and then close brake
2）Measure the voltage of the generator end
3）Ammeter cannot give correct
directly with multi meter in voltage step
value
3）Verify ammeter regularly and replace it
4）The contact of regulator pin
is not good 4）Check regulator 50HZ and 60HZ and pins

5）Surge voltage suppressor is for loosening

short circuit 5）Check voltage dependent resistor to

6）Rotating diode is damaged ensure no short circuit

6）Disconnect the rotating rectifier

7）Connection is wrong connecting wire to mainframe rotor magnetic

field. Use multi meter to measure diode. If it
is damaged, replace the pipe.
8）Exciter magnetic field coil is
7）Check carefully and perform connection
short circuit
according the connection diagram.
9）Connection is loosening or
8）Twist the broken line together and weld it
not contacted well
securely with insulation wrapped outside.
10）Generator armature coil is
9）Clean connecting wire and reconnect it.
short circuit
10）Find out the broken point and weld it
11）Generator armature coil is
and bind it up over again.
short circuit
11）Short circuit will result in heating. In
12）Exciter armature coil is
that case, replace the coil.
disconnected or short circuit
12）Find out the fault and replace the coil.

13）The speed is abnormal 13）Use speed indicator or frequency meter

14）Voltage regulator protection to check the generator speed

cuts off circuit motion 14）After finishing the adjustment according

15）Voltage regulator is to the voltage regulator specification, adjust

the regulator.
disabled
15）Replace voltage regulator.

- 32-
2、Generator Voltage 1）The speed is not correct 1）Speed indicator and frequency meter 4.5
ELECT
Fluctuation 2）The speed is not stable calculates generator speed. RIC
2）Verify governor stability. FAULTS
3）Voltage regulator stability
3）Refer to adjuster specification to adjust
4）Connection fault or sensing
voltage regulator stability.
connector lug 4.5.1
4）Check all connection for loosening or bad
5）There is a fault happening to Winding
contact inspectio
diode, surge voltage suppressor n
or generator winding 5）Carry out other debugging test on the

6）Remotely control voltage generator (use 12V battery) By high-

regulating potentiometer (if used) 6）Refer to adjustor specification to check

pressure

7）Regulator fails. the operation of remotely controlled test, the

potentiometer. insulating
8）Bearing is not good or the
7）Refer to adjustor specification to replace property
wearing of bearing support
adjuster. of the
causes nonsymmetrical air gap.
8）Replace old bearing and check bearing winding
support for wearing. If necessary, replace it. can be
3、Generator 1）Overload 1）Note ammeter at any time. Do not checked.

2）A.C. armature is short circuit. overload.

Overheating In that

2）Replace the short circuited coil. case, do

3）Air route is blocked.
3）Blow the internal generator completely.
not install
4）Exciter armature coil is short any
circuit. 4）Replace the short circuited coil.
connectio
n with AVR.

▶ For the damage caused in that case, our guarantee shall not apply.

- 33-
4.5.2 Diode rectify bridge Inspection

Disconnect the rotating rectifier connecting wire to mainframe rotor magnetic field. Use multi meter to measure diode.

4.5.3 Use other debugging to check winding and rotating rectifier diode

▶ At this step, make sure the generator is not connected with any external load and check the connection in the

terminal box for fastening.

(1) Stop operation. Do not connect AVR and separate it with insulation.
(2) There are 2 types of assembly with independent power:
Assembly A: connect 12V battery with a 50 ohm - 300W rheostat and a diode in series and also with two
magnetic field lines (F+) and (F-) of exciter.
Assembly B: connect an autotransformer of adjustable power with a diode rectifier and the with two
magnetic field lines (F+) and (F-) of exciter.

▶ These two systems should be of common characteristics, which are consistent with the magnetic field
excitation source of the generator (see the nameplate).
(3) Operate the setting at rating speed.
(4) Regulate rheostat or autotransformer gradually to increase the exciter magnetic field current and
measure the output voltage on A-B-C. Check the exciting voltage and current without and with load (see the
nameplate of the generator or apply the factory for test report).

▶ At rating excitation, if the output voltage of the generator reaches the rating value and is balanced within the

range of < 1%, the generator is in good condition.

- 34-
▶ Therefore, the fault is from AVR or its connected installation line (such as exciter winding).

▶ Use the diode suitable for the rating exciting current of the generator.

Figure 3-11. Assembly A for checking diode

Figure 3-12. Assembly B for checking diode

- 35-
4.6 DISASSEMBLY AND REASSEMBLE

In the guarantee period, this operation can only be carried out in the factory approved by Megaton or our factory,
or the guarantee will be invalid. When the generator is serviced, it should be kept flat.

4.6.1 Check Diode

- Remove air inlet net.

- Disconnect diode.
- Use multi meter to check diode (see 4.5.2).
- If diode fails, remove and replace it and recheck the polarity.

4.6.2 Check connection and regulator system

By removing the terminal box cover or AVR sight window, it is accessible directly.

4.6.3 Replace bearing

Use a puller with screw in the middle to remove ball bearing (see the following figure).

Figure 3-13. Replacing tool for bearing

Check o-ring in the front and rear end cover bearing compartment. If necessary, replace it. Heat the new bearing in the
way of induction to 80°C and install it in the bearing.

- 36-
▶ Use a new bearing to replace the removed one. When disassembling the generator, the bearing is required to

replace usually.

4.6.4 Safe Disassembly

- Remove the front end cover
- Use a sling or the support showed in the following to suspend the driving end of the rotor.

Figure 3-14. Rotor assembly tool

-Use a small gavel to beat the rotor axis end reverse with driving piece.
- Pull the sling to allow rotor moving out and make sure it can support the rotor.
- Remove bearing.

4.6.5 Reassembly

- Install a new o-ring in the end cover bearing compartment.

- 37-
- Pull the sling to allow the rotor going into the rotor and make sure it can support the rotor without being impacted.
- Install driving end cover and rear end cover on the rotor.
- Tighten the blot.
- Install air inlet net.
- Reassemble terminal block.
- Reassemble null line.
- Connect stator output and detection line
- Reassemble side plate
- Reconnect AVR
- Reassemble terminal box cover and AVR sight window cover
- Install flange and check the generator for correct assembly and all blots for tightening. Note: re-wind the rotor. All
rotors must be balanced and adjusted over again.

▶ After test, reassemble all covers.

4.7 PERMANENT MAGNETIC GENERATOR (PMG) INSTALLATION AND REPAIR

4.7.1 Mechanic Characteristics

Components are:
- A modified axis (fixing rotor on the generator),
- A screw, installing rotor on the axis,
- A rotor with magnet steel,
- Winding stator + 4 M6 screws + plastic connection + sleeve assemblies
- External cover,
- 4 M6 screws (fixing casing on the rear end cover).

4.7.2 Electrical Connection

- 2 PMG guiding lines is connected to terminals 3 and E3/4 on AVC.

- 38-
- At 1500 rpm, A.C. voltage between phases without load is 250V.

▶ If PMG is available, do not connect the voltage B at the main generator end when checking the terminal 3 on
AVC.

- 39-