MODULE 1:

CURRENT GENERATION
DC , AC , PWM
Direct Current
V
o
l
+
t
a Pulse Width Modulation
g
e _ Time
50% Duty Cycle
Steady Dc Voltage
V
o
l
+
t
a
g
e _ Time
10% Duty Cycle
Alternating Current 90% Duty Cycle

V
o
l
+
t
a
g
e _ Time
CURRENT GENERATION
If we place a conductor in a variable magnetic field a current is
induced proportional to the force of the magnetic field.
If we move the conductor parallel to the lines of the magnetic field
we will not produce voltage.

We will obtain the maximum voltage cutting the magnetic field

lines at 90 degrees.
On the other hand, an electric current creates a magnetic field
around the conductor and proportional to the current.
FARADAY’S LAW (EMF)

A variable magnetic flux through a loop of

wires will generate a motion of the
electrons in that loop proportional to the EMF

speed of variation of that magnetic flux.

S N
CURRENT GENERATION
We need 3 things:

Magnetic field N

Conductor
+
Movement -
S
CURRENT GENERATION

Rotor
Magnetic field
N

Stator S
Coil
Wave generation

V
S o
N l
t
Time
S
N
N
S

a
N g
S e
Sine wave
+
V Peak
o Voltage RMS
l (0.707 Peak value)
t
a Time
g
e

-
Amplitude

Cycle
Three phase generation

N V
o
l
t Time
a
S g
e
Four pole rotor
V
N o 2 pole rotor
l sine wave
N

S t
a Time
g
S e
4 pole rotor
sine wave

Number of poles X RPM

Frequency = = Hz
2 X 60
COIL NUMBERING
Coil numbering
T1

T4

T7

T10
T11
T8
T12
T5
T9
T6

T3 T2
WYE Series connection
High Voltage Low Amps
T1
Coil
115,5V
T4 Phase Line
T7 + 231V x 3 400V
T0 Coil
115,5V
T10
T11

T12 T8
T5
T9
T6

T3
T2
WYE Parallel connection
Low Voltage High Amps
T1

T4
T1
T7

T6 T10
T4
T11
T12
T3 T8
T6 T5
T9
T5
T2
T3 T2
WYE Parallel connection
Low Voltage High Amps
T1
T7

Coil &
T0 Line
Phase x 3 200V
115,5V
T10 T4
T6
T11

T3 T12 T5
T8

T9
T2
DELTA series connection
12 1

Coil
115,5V
9 Phase
4 = Line Voltage
6 7 + 231V
Coil
115,5V
3 10
11 8 5 2
DELTA parallel connection

12 7
1
6
Coil & Phase = Line Voltage
115,5V
9 10
3 4
5 2

11 8
Wire system
Single
voltage
4 Wires
T1 T2

T0

T1 T2 T0 T3

T3
Wire system
T2
Dual voltage
10 Wires

T3
T1

T0
Wire system
Dual voltage
12 Wires
LAB 1 : Phase recognition and
connection
GENERATOR NAMEPLATE
 CATERPILLAR
GENERATOR SET
SALES MODEL 3508

RATING

1000 KVA 800 KW 0,8 COSΦ 50 HZ

CONTINUOUS XXX PRIME STANDBY

GENERATOR DATA

3 PHASE 12 WIRE
XXX WYE DELTA
CONNECTION XXX SERIES PARALLEL
GENERATOR 400 VOLTS 1443 AMPS
EXCITATION 39 VOLTS 7.3 AMPS
693 FRAME 1500 REV/MIN

MAXIMUM TEMP. RISE 105 °C BY RESISTANCE

METERS
40 °C AMBIENT 1000 ALTITUDE
CLASS H INSULATION

ENCLOSURE TYPE

YEAR
CAT DIESEL RATING DEFINITIONS:
 Emergency Standby Power (ESP)
Output available with varying load for the duration of an emergency outage. Average power
output is 70% of the standby power rating. Typical operation is 50 hours per year with
maximum expected usage of 200 hours per year.
Standby Power
Output available with varying load for the duration of the interruption of the normal source
power. Average power output is 70%. Typical operation is 200 hours per year, with
maximum expected usage of 500 hours per year.

Prime Power
Output available with varying load for an unlimited time. Average power output is 70% of
the prime power rating. Overload operation cannot exceed 25 hours per year.

Continuous Power
Output available without varying load for an unlimited time.
Average power output is 70 - 100% of the continuous
power rating. Typical peak demand is 100% of continuous
rated ekW for 100% of operating hours.
INSULATION TEST
4C4213
For a preventive maintenance schedule, use the following guidelines:

• Generators used for seasonal operation should be tested and inspected prior
to being put back in service.

•If the generator is installed in an enclosed building with low humidity and
minimal temperature variations, test the insulation annually.

•If the generator is in a salt-laden water environment or in an environment with

high humidity (above 75% relative humidity), test the insulation every three
months.
 Megger test

Recommended Megger Insulation test Procedure:

1) Take generator out of service.

2) Visually inspect for moisture. If moisture exists, do not megger. Dry unit
first. Refer to SEHS9124 (Cleaning & drying) for drying procedure.

3) Inspect the installation to determine what equipment will be tested by the

megger.

4) Discharge the capacitance of the winding.

5) Disconnect (T0) from ground.

6) Disconnect regulator sensing lead wires (20, 22, 24).

7) Disconnect EMCP transformer leads (T1, T2, T3).

Discharge leads and windings before

disconnecting megger leads by switching
megger to OFF
9) Connect megger tester RED(+) lead to unpainted area on generator frame.

10) Connect megger tester BLACK(-) lead to (T0).

11) Set voltage to 500 volts for generators that are 600 volts or less.

Set voltage to 1000 volts for generators that are more than 600 volts.

12) Use the 30-60 time resistor method.

A) Apply voltage.

B) Observe the readings at 30 seconds & at 60 seconds.

C) Record the 60 seconds reading.

D) Record temperature.

E) Record humidity.

F) Remove voltage.
 Insulation test
The insulation condition must be evaluated based on the 60 seconds
resistance readings compare to the readings taken on previous dates
under similar conditions. A 60 second resistance reading with a 50%
reduction from previous reading indicates that the insulation may have
absorbed too much moisture.

Caterpillar recommends that the minimum acceptable insulation

resistance for generators with less than 600 volts is 1 megohm and at
least [(rated V/1000)+1megohm] for generators with more than 1000
volts.
Test results
1MΩ
Ω 1MΩ
Ω

30 s 60 s
30 s 60 s

Normal reading:
Clean & dry the windings:
The resistance after 60
The resistance after 60 seconds
seconds is greater or equal to
is lower than the resistance after
the resistance after 30
30 seconds.
seconds.
LAB 2 : Insulation Test