TESU

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: [email protected]
CROATIA
 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 Altrnator type

diesel engine
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.

2
 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

3
 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

4
 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 13450 14580 18490 23700
(peak value)
Steady s.c. current JKD 2840 3320 3800 4270
(rms value)
*
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.

5
 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. 12580 13260 14350 18140 23730
current Js
(peak value)
Steady s.c. 2657 3360 3920 4500 5060
current JKD
(rms value)

6
 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

7
 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.

8
 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)

9
 4. Technical data

4.2.7. Cover

Alternator cover is placed as shown in figure below

5
4
6

2
1

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.

12
 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.

13
 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.

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

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.

14
 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.

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

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

15
 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.

16
 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:
∆U st = 6 ⋅ 1 − cos 2 ϕ ⋅
I
(%)
IN
e.g. at p.f.=0.8 and I/IN = 1

∆U st = 6 ⋅ 1 − 0.8 2 ⋅ 1 = 3.6 (%)

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.

17
 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

18
6. Dimension drawing
19
 7. Dimension drawing of shaft
20
8. Electrical diagram

21
22
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.

23
 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: [email protected]

24