MTU ONSITE ENERGY

GENERATORS
Low Voltage Generators
Basic Principles, Electrical
3-Phase Synchronous Generators
Basic principles, elektrical

3-Phase Synchronous Generators

Basic principles (function, electrical design)
Based on 400 V generators

Page 2 / MTU Onsite Energy Sales Training / 01.06.2010

 3-Phase Synchronous Generators
Physical principles Generator principle I

All electricity generators are based on the same principle by which

mechanical power is converted into electrical power. The mechanical
power is supplied to the generator in the form of the rotation of a
mechanical shaft.

The conversion of that energy into electrical energy is based

fundamentally on the Lorentz force which acts on an electrical
charge moving in a magnetic field. If a conductor moves
perpendicularly to the magnetic field, the Lorentz force acts on the
charge in the conductor in the direction of the charge, thus causing
it to move. That movement of charge produces a potential difference
or electrical voltage between the ends of the conductor.

In a generator, that principle is made use of by the mechanical

shaft rotating the rotor inside the generator relative to the stator.
Due to the magnetic field artificially created by the rotor, the
Lorentz force produces an electrical potential in the conductors
(conductor windings) on the stator.

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 3-Phase Synchronous Generators
Physical principles Generator principle II

Coil (rotor) is vertical: A small amount of coil rotation bisects a large number of flux
lines = > high induced voltage (max. deflection)

Coil (rotor) is horizontal: A small amount of coil rotation bisects only a small number of flux
lines = > minimal induced voltage (min. deflection)
Page 4 / MTU Onsite Energy Sales Training / 01.06.2010
3-Phase Synchronous Generators
Series connection of coils

In a series connection, the voltage across the

complete series of coils is equal to the sum of
the voltages generated in each coil.
The current carrying capacity of the entire group
of coils connected in series is limited to that of
the coil having the least current carrying capacity.

Page 5 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Parallel connection of coils

In a parallel connection of equal coils, the voltage

across the connection remains that of a single coil.
The current carrying capacity of number of a equal
coils connected in parallel is the sum of the current
carrying capacity of all of the coils in the group.

Page 6 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Marathon Magnamax

Marathon Electric product features:

 PMG excitation (permanent magnet on same shaft as main rotor)
 Unique Unirotor (single piece) construction
 The rotor field winding is wet layer wound for additional structural integrity
 DVR (digital) 2000E regulator
 Large conduit box
 Outboard exciter for ease of access
 PMG mounted external to generator bearing
 Class H insulation system
 Heavy duty shielded bearings
 Enhanced ventilation
 Fully guarded for safety
 2/3 pitch optimized windings
 NEMA MG-1, IEC 34-1 , IEEE-115

Page 7 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Type of Generator

We are using a PMG and the

DVR2000 for the Voltage regulation.

Main stator
Exciter
rotor
& stator

Bearing

Main Rotor
Main rotor Shaft

Rectifier
Fan

Page 8 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
DVR 2000E Voltage Regulator

Page 9 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Generator System with PMG

Page 10 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
General function: Schematic diagram
3, 4
E1-E2-E3

PMG
power (F1) – F+ A.V.R Feedback
supply for signal (AC)
AVR (F2) – F- 3-phase
Main stator
Exciter
rotor
& stator

Bearing

Main Rotor
Main rotor Shaft

Rectifier
Fan

Page 11 / MTU Onsite Energy Sales Training / 01.06.2010

 3-Phase Synchronous Generators
Method of operation: PMG
GENERATOR WITH PERMANENT-MAGNET EXCITATION
(PMG) AND AVR VOLTAGE REGULATOR: The permanent magnet generator (PMG)
provides the energy for the exciter field
(x+, xx-) by means of an automatic
voltage regulator (AVR).
Voltage
3, 4 E1-E2-E3 detection
signal The AVR responds to a voltage
F1 (F+) AVR detection signal which, in the case of
F2 (F-)
the AVR DVR2000EC, is diverted from
the main stator winding via an
isolating transformer. By controlling
the low output of the exciter field, the
high output requirement of the main
field is obtained by means of the
Main rectified output of the exciter rotor.
Main Rotor
rotor
PMG,
AVR power supply The PMG system represents a constant
source of excitation energy and is
independent of the main stator load
Exciter (non-linear loads, thyristor switching
rotor + etc.)
stator Main stator

Page 12 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Side view with an PMG

PMG is mounted
at the back.

Only possible
until Series 430
By the higher
Generator like
500 and 700 is
that not possible.
(Inboard mounted)

Page 13 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Backview

To Main

Exitor

Page 14 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
PMG & Exiter

PMG

Exitor

Page 15 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
PMG with Supply and Power input Exiterfield

Supply for DVR

Output from DVR

Page 16 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Spec sheet DVR2000

Page 17 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Spec sheet DVR2000

Page 18 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Spec sheet DVR2000

Page 19 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Closed Loop rectifiered by a DVR 2000

AC Voltage
Rectifier DC Voltage Main Motion Main
Assembly Rotor Stator

Exitor
Rotor

Main AC Output
Motion

Sensing
Exitor
Stator
AVR
AC Voltage PMG Motion PMG
DVR
DC Voltage 2000 Stator Rotor

Capacitor
Page 20 / MTU Onsite Energy Sales Training / 01.06.2010
Customer
3-Phase Synchronous Generators
Overview on a DVR2000
Exitor field Used in Island Mode

RS232
Voltage Up down
Interface
Alarm Contact

Fuse
5A/250V

Ground Variable PF Parallel

Power Supply Control Open Open means Sensing Analog Input
means Enable Enable (DGC +/- 3V)
Page 21 / MTU Onsite Energy Sales Training / 01.06.2010
3-Phase Synchronous Generators
DVR2000 technical features

Technical Features:
 .25 % regulation
 3 phase rms sensing
 Adjustable volts per hertz feature
 Underspeed protection
 Engine unloading feature
 Built in parallel feature
 Over-excitation / over-voltage feature
 Voltage regulator DVR2000EC
for network parallel operation
(optional for Control Variant 1;
standard for Control Variant 5 and 6)
 Optional VAR-Power Factor controller
(for DVR 2000EC contoller)

Page 22 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Marathon Magnamax

Technical features for Genset:

 6 lead machines
 Star point brought out
 IP23 trip cover included

Generator Interior View

1: Digital Voltage Regulator
1a: DVR front panel display
2: Capacitor
3: PMG rotor and stator
4: Generator lifting point
5: Main rotor assembly
6: Drip cover (optiopnal)
7: SAE adapter
8: Fan
9: Screen assembly (air outlet)
10: Generator main body with
main stator assembly
11: Mounting bracket
12: Conduit box
13: Exiter stator
14: Louvered cover (air intake)
15: Exiter rectifier assembly
16: Exiter rotor assembly
Page 23 / MTU Onsite Energy Sales Training / 01.06.2010
3-Phase Synchronous Generators
Overview on a DVR2000 Frontpanel

DVR 2000
Frontpanel

Page 24 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
DVR2000 Frontpanel

DVR front panel

1-12: LED indicators
13: Select push button
14: UP push button
15: DOEN push button

Page 25 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Generator Interior View Series 1600

Generator Interior View

1: Main rotor assembly
2: Generator lifting point
3: Drip cover
4: SAE adapter
5: Fan
6: Screen assembly (air outlet)
7: Generator main body with
main stator assembly
8: Mounting bracket
9: Exiter stator
10: Exiter rectifier assembly
11: Exiter rotor assembly
12: PMG rotor and stator

Page 26 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Individual components

Exciter stator
Exciter rotor

Main rotor
Main stator

Damper
winding
Permanent
magnet generator
Page 27 / MTU Onsite Energy Sales Training / 01.06.2010
3-Phase Synchronous Generators
Exciter stator location

Main stator
Exciter
Exciter rotor
stator & stator

Bearing

Main Rotor
Main rotor Shaft

Rectifier
Fan

Page 28 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Exciter stator design

To automatic voltage regulator

F1- (F+)
F2- (F-)

Coil connection:

N S N S

 Highly magnetic coil core

 High residual magnetism
 12-14 pole magnetic field
 High frequency generator
Page 29 / MTU Onsite Energy Sales Training / 01.06.2010
3-Phase Synchronous Generators
Exciter rotor location

Main stator
Exciter
rotor
Exciter & stator
rotor
Bearing

Main Rotor
Main rotor Shaft

Rectifier
Fan

Page 30 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Exciter rotor design

W
U

Shaft V

W
 3-phase AC output, each phase connected to 2 diodes on the main rectifier.
 High-frequency output (12 to 14 pole exciter stator).
 Exciter generator operates as amplifier for main rotor currents.

Page 31 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Exciter rotor: Rectifier location

Rectifier

Main stator
Exciter
rotor
& stator

Bearing

Main Rotor
Main rotor Shaft

Rectifier
Fan

Page 32 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Exciter rotor: Rectifier design

 Rectifier connection
W
U
 Rectifier plate
 Molded base plate (negative)

Shaft
SHAFT V

 Varistor

 Exciter rotor
 Rectifier diode
U

W  Rectifier plate
(positive)
Page 33 / MTU Onsite Energy Sales Training / 01.06.2010
3-Phase Synchronous Generators
Exciter rotor: Rectifier AC side

Shaft

Page 34 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Exciter rotor: Rectifier diodes

 Rectifier diode  Rectifier

case: negative plate made
thread: anode of aluminum

 Varistor

Shaft

 Main rotor supply

 Rectifier diode:
case: positive
thread: cathode
DIODE - 70 AMP 1400 VOLT
Page 35 / MTU Onsite Energy Sales Training / 01.06.2010
3-Phase Synchronous Generators
Exciter rotor: Rectifier diodes function

 Rectifier diode AC input

(150 Hz to 180 Hz)

 Rectifier Case: positive (A)

diode: Stud: negative (K)
+VE

+ 0

-VE

 Rectifier Case: negative (K) +VE

diode: Stud: positive (A)
0

-VE

Page 36 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Exciter rotor: Rectification

AC input to rectifier diodes (150 to 180Hz):

 DC output to main rotor:

+

Page 37 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Exciter rotor: Diode protector “Varistor”

A varistor is an electronic component. It is a voltage

dependent variable resistor. Above a certain
threshold voltage that is characteristic for the
particular varistor, the resistance abruptly drops. The
characteristic is symmetrical with the voltage, i.e. the
polarity has no effect. Varistors are also referred to
as VDRs. VDR stands for voltage dependent resistor.

Main rotor
Shaft
connection

Marathon usually uses metal oxide varistors (MOVs).

Varistors are suitable for protecting against overvoltage. In normal operation, their resistance is
very high, whereas in overvoltage conditions the resistance drops almost instantaneously to a very
low level and diverts charge. They are used to protect the rectifier diodes.
Page 38 / MTU Onsite Energy Sales Training / 01.06.2010
3-Phase Synchronous Generators
Exciter rotor: Varistor function

Excess energy is Typically voltage faults in the supply

diverted through the system (2 - 3000V peak voltage)
varistor. The varistor
may be destroyed
Possible causes are:
as a result.
 Unsynchronized connection of load
(bus bar live)
Breakdown
voltage:  Lightning strikes affecting the mains grid
1365V  Short circuits

Rectifier t = µ secs Direction of direct current to main rotor

output

Page 39 / MTU Onsite Energy Sales Training / 01.06.2010

 3-Phase Synchronous Generators
View on Diodes, Varistor and CT‘s

Diodes +Varistor

CT‘s

Page 40 / MTU Onsite Energy Sales Training / 01.06.2010

 3-Phase Synchronous Generators
Powerelectronic Exitor and Main Rotor

Varistor is used for

the case that you
have a short circuit

Supply to
Main Rotor

Supply
from Exitor

Page 41 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Main rotor location

Main rotor

Main stator
Exciter
rotor
& stator

Bearing

Main Rotor
Main rotor Shaft

Rectifier
Fan

Page 42 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Main rotor purpose

Purpose: to generate a magnetic field

CCW
S

N
Welle
D.C. input
from rectifier S S

- Magnetic flux lines

NORD
N N
CW Clockwise (CW)

S
SÜD

- Magnetic flux lines (N>S)

Counterclockwise (CCW)

 The rotors coils are interconnected in series (4-pole rotor).

 Each coil is reversed in relation to the preceding one to produce
the
Page 43 / MTU Onsite required
Energy Sales Training / polarity
01.06.2010
3-Phase Synchronous Generators
Main rotor DC supply

Main rotor
Rectifier

Shaft D.C.

The rotor is supplied with a smoothed direct current from the aluminum
rectifier plates.

Page 44 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Main rotor: Pole pairs / Generator frequency

2-pole 4-pole 6-pole

S
S

N
N

N
Welle N Welle N Welle

S
S
N

At 1500 rpm / 25 Hz At 1500 rpm / 50 Hz At 1500 rpm / 75 Hz

Generator frequency (Hz) = Rotation speed x No. of pole pairs

60
Page 45 / MTU Onsite Energy Sales Training / 01.06.2010
3-Phase Synchronous Generators
Main rotor: Pole pairs / Generator frequency

FREQUENZ ANZAHL DREHZAHL

Hz (Perioden) POLE (p x 2) (n)

50 2 3000
2 Pole 1 Hz = 60 1/min
50 4 1500 4 Pole 1 Hz = 30 1/min
6 Pole 1 Hz = 20 1/min
50 6 1000

60 2 3600

60 4 1800

60 6 1200

Page 46 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Main stator location

Main stator
Main stator
Exciter
rotor
& stator

Bearing

Main Rotor
Main rotor Shaft

Rectifier
Fan

Page 47 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Main stator design
 Special steel laminations (electrical steel) are used for the laminated core which
minimize the core losses (heat).
 Each lamination in the laminated stator core is electrically isolated to minimize
eddy current losses.
 Standard insulation class ‘H’, i.e. 125 ºC temperature rise at 40°C ambient
temperature. Normally class F capability (Delta 105°C => longer life)
 2/3 pitch winding to virtually eliminate 3rd, 6th and 9th harmonics.
 Generators are generally epoxy resin impregnated as standard.

Connections:
Laminated steel core

Copper windings
Page 48 / MTU Onsite Energy Sales Training / 01.06.2010
 3-Phase Synchronous Generators
Damper winding lacation

Aluminum rods welded to plate at ends

S
N

Shaft
N

+ Mechanical reinforcement (especially under heavy load fluctuations)

+ Stabilizes mains supply characteristics with generators in parallel
+ Improves sine wave form (smoothes out uneven rotation)
Page 49 / MTU Onsite Energy Sales Training / 01.06.2010
3-Phase Synchronous Generators
Permanent magnet generator location

3, 4 power supply for AVR

Generator shaft (NDE, Non-Drive-End)

 Locating pin for locating PMG rotor position

 Ceramic magnet rotor
10 pole rotor, 250 Hz (at 1500 rpm) or 300 Hz (at 1800 rpm)

 Rigidly bolted to generator shaft

 The permanent magnet generator generates the power supply for the
automatic voltage regulator (3-phase A.C. 190 to 230 volts)
Page 50 / MTU Onsite Energy Sales Training / 01.06.2010
3-Phase Synchronous Generators
Advantages of the exiter alternator

The permanent shortcircuit current in case of error status.

Unaffected even when wave form is distorted by non-linear loads.

Voltage supply to the voltage regulator already during start activity,

independant of residual magnetism.

Starting heavy electric motors is possible by shifting the (voltage-) frequency.

Isolated power supply for the voltage regulator (protects the voltage regulator
against high transient voltage peaks from the supplied network).

Page 51 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Magnetization curve: Optimum band

Magnetization curve
Generator voltage/
magnetic flux density
Can cause damage due to
overheating of exciter winding!
Maximum flux density

Ideal flux density

Saturation
Minimum flux density

Can cause damage due to overheating of

stator winding! Also poor response to load changes
(due to bigger voltage dip).

D.C. exciter current/

mag. field strength H
0

 Each winding is designed for a specified (optimum) voltage range.

 The generator must operate within that voltage range.

Page 52 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Generator Specification Sheet 50Hz

Page 53 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Generator Specification Sheet 50Hz

Page 54 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Generator Specification Sheet 50Hz

Page 55 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Generator Specification Sheet 50Hz

Page 56 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Generator Specification Sheet 60Hz

Page 57 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Generator Specification Sheet 60Hz

Page 58 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Generator Specification Sheet 60Hz

Page 59 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Generator Specification Sheet 60Hz

Page 60 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Generator Insulation

Page 61 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Generator derating

Page 62 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Generator overview Serie 4000

Outlet box Current transformers Potential transformer

Page 63 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Generator overview Serie 2000

Generator Conduit Box

1: Digital Voltage Regulator
2: Fuses
3: Bar busses
4: Standoff insulator
5: Exciter stator
6: Exciter rotor assembly
7: Current transformer
for measuring
8: Exciter rectifier assembly
9: Diode standard polarity
10: Surge suppressor
11: Diode reverse polarity

Page 64 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Generator overview Serie 1600

Generator Outlet Box

1: Diode standard polarity
2: Surge suppressor
3: Exciter rectifier assembly
4: Diode reverse polarity
5: Current transformer
for measuring
6: Bus bar

Page 65 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Grounding concept

1: DIS 10 (option)
2: SAM
3: Engine governor
4: Battery
5: To engine sensors
6: Generating set
7: Equipotential
bonding strip
8: Grounding (PE)
9: Equipotential
bonding strip
10: Equipotential
bonding strip
11: Mounting frame
12: GND (-)
13: +24 VDC (+)

Page 66 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators
Generator Output Voltage

Page 67 / MTU Onsite Energy Sales Training / 01.06.2010

3-Phase Synchronous Generators

Thank you
for your attention.

Page 68 / MTU Onsite Energy Sales Training / 01.06.2010