Brushless Constant-Voltage Synchronous-Alternators

TNC6 45_

Low-Voltage for shipboard use

Design for MAN B&W L16/24 ENGINE

Uljanik TESU d.d tel. + 385 52 374 402 Flaciusova 1, P.O. Box 114 fax. + 385 52 374 525 52100 PULA E-mail: uljanik-tesu@uljanik.tel.hr CROATIA

TESU

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Brushless Constant-Voltage Synchronous-Alternators TNC6 45_ 6 Brusless alternators family TNC6 45_ 6 are the result of our many years of experience in design and production of alternators and technical requests of the diesel engines producer MAN B&W Holeby. Alternators are special designed to the MAN B&W specifications and they are intended for coupling to the engines family L16/24 for marine gensets. Engine types and appertaining alternators can be founded in the table below.

MAN B&W Holeby diesel engine

Altrnator type

5L 16/24 TNC6 455 6 6L 16/24 TNC6 456 6 7L 16/24 TNC6 457 6 8L 16/24 TNC6 458 6 9L 16/24 TNC6 459 6

This catalogue contains technical data with basic description of design and the alternator dimensions.

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Contents

1. General information ……………………………………………………… 4 2. Electrical characteristic at 50Hz ……………………………………….. 5 3. Electrical characteristic at 60Hz ……………………………………….. 6 4. Technical data ……………………………………………………………. 7

4.1. TNC6 45_ 6 general cut wiew ………………………………………. 7 4.2. Stator …………………………………………………………………... 8 4.2.1 Main stator ……………………………………………………. 8 4.2.2. Exciter stator ………………………………………………….. 8 4.2.3. PMG stator ……………………………………………………. 8 4.2.4. Anti condensation heating ……………………………………. 9 4.2.5. Alternator protection equipment ……………………………… 9

4.2.6. Terminal box …………………………………………………… 9 4.2.7. Cover …………………………………………………………… 10

4.2.8. Lifting eyes ……………………………………………………... 10 4.2.9. Genset elastic mounting element acces ……………………..10 4.2.10. Coupling screws access ………………………………………. 10 4.2.11. Voltege regulator access ………………………………………10 4.2.12. Nameplate ……………………………………………………….11 4.3. Rotor ……………………………………………………………………… 12 4.3.1. Main rotor ………………………………………………………. 12 4.3.2. Exciter rotor ……………………………………………………. 13 4.3.3. PMG rotor ……………………………………………………… 13 4.3.4. Rotating rectifier ……………………………………………….. 13 4.3.5. Fan ………………………………………………………………. 13 4.4. Coupling ………………………………………………………………….. 13 4.5. Ball Bearing ………………………………………………………………14 4.6. Excitation system ……………………………………………………….. 15 4.6.1. Mode of operation ……………………………………………….15 4.6.2. Voltage Regulator ………………………………………………. 15 4.6.3. Overvoltage suicide circuit ……………………………………..16 4.6.4. Parallel operation ………………………………………………..17 5. Spare parts …………………………………………………………………….. 18 6. Dimension drawing ……………………………………………………………. 19 7. Dimension drawing of shaft ………………………………………………….. 20 8. Electrical diagram ………………………………………………………………21

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1. General iformation Alternator The alternator is a brushless constant voltage synchronous machine. The machine is of the self-excited type with an automatic voltage regulator. Exciter The machine has a shaft-mounted exciter on the side of the non-drive end shield. The main machine field winding is powered from the exciter rotor winding via a rotating, three-phase bridge-connected rectifier set. Excitation system The exciting current for the exciter is supplied by the PMG via the electronic voltage regulator. The regulator and the PMG are placed on the side of the non-drive end shield, under the end-mounted cover. Vibration stability The alternator fulfils the requirements concerning vibrations in accordance with the standard ISO 8528-9. Standards and Requirements The alternators conform to applicable IEC requirements, DIN standards and VDE codes and particularly to VDE 0530, Specification for rotating electrical machines. The alternators also conform to the requirements of the following classification societies:

Classification society Abbreviation Coolant temperature (CT) 0C American Bureau of Shipping ABS 50 Bureau Veritas BV 40,45, 50 Germanischer Lloyd GL 40, 45 Lloyd's Register of Shipping LRS 40, 45, 50 Det Norske Veritas NV 35, 45 Registro Italiano Navale RINa 45, 50

Marine alternators can also be supplied to satisfy the requirements of other classification societies such as

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2. Electrical characteristics at 50 Hz Electrical frequency: f = 50 Hz Insulation class: H Speed: n = 1000 rpm Temperature rise: F* Voltage: U = 400 V Winding pitch: 6/7.5 Ambient temperature: 45 °C Designed according to the marine Protection: IP23 classification rules Mounting of air filter inlet gives no reduction in kW output of the alternator.

Engine type 6L 16/24 7L 16/24 8L 16/24 9L 16/24 Alternator type TNC6 456-6 TNC6 457-7 TNC6 458-6 TNC6 459-6 kW 540 630 720 810 kVA 636 743 850 955 Efficiency (%) at power factor=0.8 (IEC standard) Power : 100% 94.1 94.2 94.5 94.3 Power : 75% 94.3 94.4 94.6 94.4 Power : 50% 94.1 94.5 94.5 94.0 Power : 25% 92.0 92.6 92.5 91.1 Efficiency (%) at power factor=1 (IEC standard) Power : 100% 95.4 95.5 95.7 95.8 Power : 75% 95.7 95.9 96.0 95.9 Power : 50% 95.6 95.9 95.9 95.6 Power : 25% 93.8 94.3 94.2 93.1 Reactances (%) Xd 284 331 306 206 Xq 216 252 234 158 Xd' 16.9 18.5 17.1 14.4 Xd'' 14.4 15.6 14.4 12.3 Xq'' 15.4 16.4 15 13.1 X2 14.3 16 14.6 12.7 Xo 6.8 7.1 7 5.8 Kcc 0.35 0.30 0.33 0.48 Time constants (Second) T'do 1.51 1.6 1.85 1.3 T'd 0.09 0.09 0.103 0.091 T''d 0.004 0.004 0.004 0.004 Ta 0.03 0.032 0.036 0.03 Short circuit current (A)

Maximum s.c. current Js (peak value)

13450 14580 18490 23700

Steady s.c. current JKD

(rms value) 2840 3320 3800 4270

* Except for 9L 16/24 - 1000 rpm. Here the temperature rise of the alternator is class H or reduction in power output for temperature rise class F.

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3. Electrical characteristics at 60 Hz Electrical frequency: f = 60 Hz Insulation class: H Speed: n = 1200 rpm Temperature rise: F Voltage: U = 450 V Winding pitch: 6/7.5 Ambient temperature: 45 °C Designed according to the marine Protection: IP23 classification rules Mounting of air filter inlet gives no reduction in kW output of the alternator.

Engine type 5L 16/24 6L 16/24 7L 16/24 8L 16/24 9L 16/24 Alternator type TNC6 455-6 TNC6 456-6 TNC6 457-6 TNC6 458-6 TNC6 459-6 kW 500 600 700 800 900 kVA 591 708 827 950 1066 Efficiency (%) at power factor=0.8 (IEC standard) Power : 100% 94.6 94.4 94.5 95.0 94.7 Power : 75% 94.7 94.7 94.8 95.0 94.7 Power : 50% 94.1 94.4 94.7 94.7 94.3 Power : 25% 91.2 92.0 92.6 92.5 91.2 Efficiency (%) at power factor=1 (IEC standard) Power : 100% 96.0 95.7 95.8 96.0 96.1 Power : 75% 96.0 96.0 96.1 96.2 96.1 Power : 50% 95.6 95.7 95.9 95.9 95.7 Power : 25% 93.1 93.7 94.2 94.1 93.0 Reactances (%) Xd 272 336 386 364 259 Xq 208 256 294 277 198 Xd' 15.7 18 19.5 18.2 15.1 Xd'' 13.2 14.9 16.3 15 12.6 Xq'' 14.3 16.2 17.2 15.9 13.5 X2 13.7 15.5 16.7 15.4 13.1 Xo 6.4 7.6 7.9 7.8 6.5 Kcc 0.37 0.30 0.26 0.27 0.39 Time constants (Second) T'do 1.54 1.68 1.8 2.06 1.58 T'd 0.089 0.09 0.091 0.103 0.092 T''d 0.004 0.004 0.004 0.004 0.004 Ta 0.03 0.03 0.032 0.036 0.03 Short circuit current (A)

Maximum s.c. current Js (peak value)

12580 13260 14350 18140 23730

Steady s.c. current JKD (rms value)

2657 3360 3920 4500 5060

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4. Technical data 4.1. TNC6 45_ General cut view This figure represents the general section where all main parts of alternator can be seen.

1 Shaft 11 End shield 2 Drive hub 12 Voltage regulator 3 Flexplate 13 Ball bearing 4 Fan 14 Air inlet cover (filter at option) 5 Fan housing 15 Exciter field 6 Rotor core and winding 16 Exciter armature 7 Stator core and winding 17 Rotating rectifier 8 Stator frame 18 Stator PMG 9 Terminal box housing 19 Rotor PMG 10 Terminals

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4. Technical data 4.2. Stator 4.2.1 Main stator Stator core The stator core of the main machine is made of high-quality, both sides insulated electrical sheet steel. It is subdivided into packets by means of ventilating ducts and spacers thus ensuring effective cooling. The complete core with winding is pressed into the housing. Stator winding Applying the most recent developments in engineering and materials is making stator winding. The alternator windings are manufactured in insulation system which satisfies class H. The insulation materials used are non-hydroscopic, non-tracking and withstand severe thermal stressing. The stator windings of the alternators are made of special enameled cooper wire. The standard insulation uses a special resin impregnation process. This results in high mechanical strength, vibration resistance and excellent dielectric strength. 4.2.2 Exciter stator The stator of the exciter is mounted on the end shield at the non-drive end. The exciter field winding is made of enamelled cooper wire. It is H class insulated and resin impregnated. 4.2.3 PMG stator The stator of the PMG is accommodated between an exciter and bearing mounted on the end shield. The stator core of the PMG machine is made of both sides insulated electrical sheet steel. The armature winding of the PMG is made of enamelled copper wire and class H insulated.

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4. Technical data 4.2.4. Anti-condensation heating Anti-condensation heating is installed in the alternator. It is recommended that heating element starts up when the alternator is stopped. It is connected to the auxiliary terminals. The anti-condensation heater requires a voltage of 220 V and has heat output of 250W. 4.2.5. Alternator protection equipment The stator winding is provided with thermal protection in the form of resistance thermometers. The resistance thermometers are of the PT100 type and are connected to the auxiliary terminals. 4.2.6. Terminal box The main terminal box of the alternator is located on the machine top. The neutral and phase wires are connected to the bars, one bar per phase and one bar per neutral line. The openings provide access to the terminals. The connection of accessories is carried out on auxiliary terminals. The terminal strips are located on the opposite side of main terminal Main terminals The alternator main terminals are marked U, V, W. The access to the main terminals is enabled by removing the panel pos.3 from the alternator cover. (fig. on page 10) The main cables entry is provided from the bottom, under the alternator cover. Inside alternator, the cables are fixed to the cable trays. For cables laying and cables trays access it is necessary to remove the panel (pos. 2) in addition to panel (pos. 3). (fig. on page 10) Auxiliary terminals The auxiliary terminals are located under the alternator cover opposite the main terminals. For the auxiliary terminals access it is necessary to remove the panel (pos. 3) opposite to the main terminals panel. (fig. on page 10)

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4. Technical data 4.2.7. Cover Alternator cover is placed as shown in figure below

4.2.8. Lifting eyes The lifting eye serves for the complete alternator removal. It is located under the alternator cover. The access to the eye is enabled by removing the panel (pos. 5). 4.2.9. Genset elastic mounting element access The access to the genset elastic mounting element is enabled by removing the cover (pos.2) 4.2.10. Coupling screws access Coupling screws access is enabled by removing the air outlet louvres (pos1) and panel (pos. 6) 4.2.11. Voltage regulator access The voltage regulator is located under the end-mounted cover on alternator non-drive end. For access to the regulator it is necessary to remove the panel (pos. 4) on alternator cover.

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4. Technical data 4.2.12. Nameplate Main nameplate The main nameplate is fitted to the cover on non-drive end side. It gives the manufacturer′s data, the alternator electrical data, the alternator type and serial number. Rotation direction nameplate An arrow is fitted on the cover to indicate the rotation direction.

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4. Technical data 4.3. Rotor The cylindrical rotor consists of the shaft, the rotor core, the field and damper windings. The shaft also carries, on the non-drive end, the rectifier wheel, the rotor core of the exciter with a three-phase winding, the rotor core of the PMG with permanent magnets and the bearing. The machine is fitted with fan. The shaft has a hub and disc coupling. The rotating parts are shrunk onto the shaft and additionally secured by keys. The shaft dimensions are selected to ensure that the torque can be transmitted even under conditions of extreme stressing, e.g. in the case of short circuit. 4.3.1. Main rotor Rotor core The rotor core of the main machine is made of electrical non-oriented sheet steels. The slots of the field winding and the damper winding slots are punched on the plates. The laminations are firmly pressed between the clamping plates. Ventilating ducts, which are formed by spacers, subdivide the core into packets and ensure effective cooling. Rotor winding The field winding is a single-layer winding. It is inserted in semi-closed slots, which are arranged around the core periphery. The winding is distributed over slots per pole, which ensures that the rotating masses are uniformly distributed over the rotor circumference. Therefore the mechanical stressing due to the centrifugal forces is considerably smaller. In addition to this, a uniform temperature distribution is thereby obtained, which increases the life of the winding. To make the end turns resistant to the centrifugal forces, rings of fiberglass are fitted on the overhang. For the slot insulation of the rotor winding the Nomex material is used. All the connections of the winding are hard-soldered. The rotor core assembly with winding is resin impregnated. Excellent mechanical and electrical properties are thus obtained. The thermal endurance of the winding insulation of the main machine and the exciter satisfies the requirements of class H insulation. The insulation is resistant to moisture, oil vapours and sea air. Damper winding The damper winding consists of bars, which are accommodated in equally spaced slots. At the core ends, the bars are bent and welded to end rings, thus forming a damper cage. With synchronous machines the damper winding reduces distortion of the voltage and current waveform to a minimum, even under conditions of unbalanced loading.

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4. Technical data 4.3.2. Exciter rotor Three-phase exciter supplies the field winding of the main machine via the rotary rectifier. The construction of the exciter rotor core is similar to that of the rotor core with the field winding of the main machine. The exciter winding is of the round-wire type and inserted in semi-closed slots. Multiple coils are combined per pole and phase. Each coil comprises several turns. The slot and overhang insulation is of Nomex brand. The rings of fiberglass are fitted over the winding overhangs. 4.3.3. PMG rotor The rotor core of the PMG machine is made of both sides insulated electrical sheet steel. Permanent magnets are inserted in open slots which are arranged around the core periphery. 4.3.4. Rotating rectifier The rotating rectifier is a full-wave three-phase rectifying bridge. The rotating rectifier is placed on the backside of the machine. This rectifier includes three diode modules. Diodes are protected from over-voltage by varistor. This varistor is mounted in parallel with the main field. The rectifier design and selected high-quality silicon elements ensure high operation safety and protection of the diodes. 4.3.5. Fan The alternators are designed for self-ventilation. A radial fan is mounted on the driving disk plate and provides flow of air through the machine. The alternator can be equipped with air inlet filter without reduction of output power. 4.4. Coupling Alternators are of a single-bearing design B9/B15. Multiple-disc clutch and adapter on the fan hausing are completely adapted to the engines L16/24 MAN B&W . Such design enables simple and quick coupling.

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4. Technical data 4.5. Ball Bearing Description The bearing on single-bearing alternator is installed at the non-drive end. It is the floating deep-grove ball bearing. The axial play is compensated by means of compression springs. The model of bearing is favourably chosen as for direction and size of load (type of construction, forces acting on the shaft) and therefore it should not be changed. The axial movement for this bearing type is ±3 mm.

Bearing type

Alternator Bearing type TNC6 45_6 6226 C3 DIN 625

Lubrication For the initial lubrication of the bearings, a lubricating grease DIN 51825-K3k with lithium soap as thickener and with mineral oil as basic oil is usually used. The type of thickener and the basic oil are not stipulated by DIN 51825 and must always be stated additionally. Besides the definition of grease used for the of machines with regreasable bearings, the regreasing interval is also given on the data plate.

1 - Inner bearing cap with felt sealing rings 2 - Compression spring 3 - Deep-grove ball bearing 4 - Grease slinger 5 - Circlip 6 - Outer bearing cap 7 - Lubricating nipple 8 - V-ring

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1.PMG field 2.Exciter armature 3.Rotating rectifier 4.Main field 5.Main stator winding 6.Exciter field 7.Voltage regulator 8.Overvoltage suicide circuit 9.PMG armature

4. Technical data 4.6. Excitation system 4.6.1. Mode of operation The permanent magnet generator provides excitation for the exciter field via the Voltage Regulator which is the controlling device governing the level of excitation to the exciter field. The voltage regulator responds to a voltage-measuring signal derived via the isolating transformer from the main stator winding. Isolating transformer is incorporated in voltage regulator. By controlling the low power of the exciter field, the control of the high power requirement of the main field is achieved through the rectified output of the exciter armature.

Detailed wiring diagram is shown on page ……. 4.6.2. Voltage Regulator Regulator data Control modes : Constant Voltage mode Volt per Hertz from 35-70 Hz Volt per Hertz till 45 Hz Volt per Hertz till 55 Hz Voltage measuring : three phase Voltage and frequecy : 3 x 400 V , 50 Hz 3 x 450 V , 60 Hz Voltage adjustment : ± 10 % with eternal potentiometar

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4. Technical data Accuracy : < 1 % Self excitation : Self exciting from 3 Volt remanent voltage Removable connectors : not interchangeable Option connector : for optional regulations as soft start, power factor, multiple setpoint. Protections : Underfrequency protection (underspeed) Overshoot discrimination : to reduce overshoot after over excitation (saturated) situations Fuse : 6.2 x 32 mm 10A super-fast fuse Underfrequency protection The regulator has a frequency-trip function. This function drops the alternator voltage, when the alternator frequency comes below the adjusted value. Recovering from a frequency-trip situation occurs after a delay to prevent oscillation. The under speed protection may be disabled. Note: The frequency of the alternator is determined by its rotating speed. The voltage regulator cannot adjust the actual frequency. Overshoot discrimination The voltage regulator has an over shoot discrimination circuit, which gets active when the alternator gives an over voltage after an overexcited situation, such as short circuits. The AVR controls the voltage to approx.100 Volt and the red LED goes on. The voltage gets back according the chosen build up ramp. 4.6.3. Overvoltage suicide circuit Due to circumstances of defects in the alternator or AVR, high voltages may occur on the alternator terminals. To prevent damage to the installation and alternator, the overvoltage suicide modul can be used. The overvoltage suicide modul blows the fuses when an over voltage occurs from approx. 40% above nominal voltage.

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4. Technical data 4.6.4. Parallel operation Parallel operation is possible, when using our droop-kit. This kit has to be connected to X1 and X2 according to the diagrams. The potentiometer in the regulator serves for the droop adjustment in parallel operation. The kW output is adjusted by prime mover governor. The speed characteristic of the prime mover should be linear and should rise by at least 3% and not more than 5% between rated load and no load. For the alternators with current transformer for droop compensation, potentiometer in the regulator is adjusted so that there is no reduction in the alternator voltage at unity p.f., but a 6% reduction at zero p.f. The corresponding voltage reduction at 0.8 p.f. is 3.6%. In isolated operation and at any loading condition of the alternator, the droop compensation provided for the alternator voltage can be checked with the following relationship:

( )% cos16 2

Nst I

IU ⋅−⋅=∆ ϕ

e.g. at p.f.=0.8 and I/IN = 1

( )% 6.318.016 2 =⋅−⋅=∆ stU If the alternator is to operate alone, droop compensation equipment is not required. It can be deactivated by short-circuiting the associated current transformer on the secondary side or setting potentiometer in the regulator on the controller to the left-hand stop.

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5. Spare parts 5.1. Classification societies spare parts Classification societies generally call for the following spare parts:

Spare Classificatin society Parts ABS BV GL LRS NV RINa

1 rolling-contact bearing • • • • • 1 rectifier assembly • • • 1 electronic voltage regulator • • • 5.2. Recommended spare parts Regardless of the requirements made by the classification societies we recommend that the following spare parts be ordered together with the alternators.

Name Type Qty. Regulator LX500 1 Diodes module SKKD 81/12 L1 3 Varistor module SKVC 20A 460C 1

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6. Dimension drawing

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7. Dimension drawing of shaft

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8. Electrical diagram

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Brushless Constant-Voltage Synchronous-Alternators TNC6 45_ 6

MAINTANCE & SERVICE Brusless alternators family TNC6 45_ 6 don’t require practically any maintance. Alternators servicing is provided by our own Service Dept., and through SIEMENS service network worldwide.

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Uljanik TESU d.d. Flaciusova 1, P.O.Box 114 52100 PULA CROATIA Tel. + 385 52 374 402 Fax. + 385 52 374 525 E-mail: uljanik-tesu@uljanik.tel.hr