Application Guidance Notes: Technical Information from Cummins Alternator Technologies

AGN 238 – General Application and Operational

Conditions for STAMFORD® Alternators

CONTENTS
Application and Operational Conditions
Thermal Damage Risks
Earthing and Neutral Referencing of Generator
Voltage Transient Risks
Current Transient Risks
Preventable Current Transient Risks
Loss of Synchronisation
Non-preventable Current Transient Risks
Vibration Levels
Bearings
Humidity
Operating Manual

Practical Guidance to On-site Operating Conditions and Impacts to Alternators -

Summary
Safety Notice
Alternator Operating Voltage and Frequency Range
Alternator Rating
Basic Continuous Rating (BR)
Peak Continuous Rating (PR)

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Overload
Power Factor
What Causes Power Factor
Load Sharing
Cooling Air for an Alternator
Ambient Temperature
Airflow Through the Alternator
Airflow Requirements
Alternator Air Filters
Environmental Conditions
IP Codes
Ratings on STAMFORD Alternators
Environmental Operating Conditions

SCOPE
These Application and Operational Conditions apply to Cummins Alternator Technologies,
STAMFORD low voltage alternators, in applications that are not governed by international or
national Grid Codes.
In general, the alternator will be operated within the performance parameters stated in IEC
60034-1:2010.
These conditions must be followed in conjunction with the STAMFORD alternator’s Owner’s
Manual.

THERMAL DAMAGE RISKS

There is a risk of thermal damage to the alternator if any of the following circumstances are
true for the application or environment in which the alternator is being used.
• The generating set equipment package is being operated in close proximity to plant or
equipment such that it is at risk of exhaust and/or hot air being carried into the cooling
air intake.
• The alternator air inlet temperature exceeds 40oC.
• The alternator system voltage is operated beyond Zone A voltage limits (+/-5%) as
specified in IEC 60034-1:2010 Section 7.3.
• The alternator system frequency is operated beyond Zone A frequency limits (+/-2%)
as specified in IEC 60034-1:2010 Section 7.3.
• The alternator is operated at an altitude exceeding 1000m above sea level.
• The alternator or the generating set equipment package is operated with air inlet filters,
due to a high risk of solid or liquid contaminants in the alternator cooling air supply.

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 • The alternator is operated with a cooling air supply less than the free volume quoted in
the alternator’s technical data sheet.
• The alternator is operated in an overload condition exceeding that specified in IEC
60034-1:2010.

If any of the above conditions are true, then the following conditions (A-C) will apply:

A. Based on IEC 60034-1:2010 Section 8.6.3.1, embedded RTDs must be used in

conjunction with an operating control system configured to Trip at 155oC.
B. The operating control system must include a pre-trip Alarm setting 5oC below the Trip
temperature to guard against unexpected Trip events.
C. In the event of an Alarm condition, the customers on site operating procedures must
prescribe corrective actions to manage the alarm condition to ensure trip levels are
avoided. Those actions must be taken and may include, but are not restricted to,
changing filters, removing restrictions to cooling air, or reducing the alternator output
current.

EARTHING AND NEUTRAL REFERENCING OF ALTERNATOR

Appropriate earthing and neutral referencing of a LV alternator provides a fundamental method

of restricting the magnitude of imposed potential voltage differences across the stator winding
assembly.
• The installer of a generating set equipment package must ensure the neutral and
earthing arrangements for the alternator are compatible with the earthing arrangement
of the electrical network to which that generating set equipment package is to be
connected.
• Earthing arrangements must be mechanically robust and protected from any
degradation that affects electrical continuity in line with local grid / network connection
standards where available, and at least in accordance with BS7430:2011 Code of
practice for protective earthing of electrical installations.
• If the generating set equipment package is operating in parallel with a supply system
which is either, un-earthed or earthed through fault limiting impedance, then a means
of detecting abnormal earth fault conditions must be incorporated within the generating
set equipment package.

VOLTAGE TRANSIENT RISKS

High voltage transients will, over time, degrade any insulation system. The STAMFORD low
voltage (<= 1kVrms) alternator insulation system is designed to withstand peak transient
voltage levels up to and including 1.3kV in accordance with IEC 60034-17, Figure 7 - Limiting
curve of admissible impulse voltage ULL.
• The customer must ensure that the level of voltage transient does not exceed 1.3kV in
accordance with IEC 60034-17, Figure 7.

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CURRENT TRANSIENT RISKS
High current transients cause high mechanical forces between conductors, coil groups and
phases. These mechanical forces can lead to insulation damage, which in turn may lead to
machine failure. In addition, high current transients can result in high torque transients
impacting both static and rotating components.
Current transients fall into two classes: Preventable and Non-preventable
Preventable Current Transient Risks
The installation must be capable of limiting the magnitude and duration of excessive current
transients resulting from Step Load Changes.
Synchronisation:
• The current transient associated with synchronising individual generating sets with the
network, or groups of generating sets with the network, must be managed by an
effective synchronising system. The current transient resulting from synchronisation
must not exceed 1.0 times full load current.
• A synchronisation event at point of closure being within the following limits will achieve
this requirement:
o Phase angle; within +/- 10 degrees electrical,
o Voltage match; within +/- 0.5% system voltage level,
o Slip rate is within 0.1Hz/sec.
Loss of Synchronisation
• To avoid the damaging effects encountered due to loss of synchronisation, a protection
scheme must be in place with the ability to detect system disturbances and disconnect
the generating set.
Non-preventable Current Transient Risks
Some network faults can cause very high current transients.
• It is accepted that protection systems cannot prevent the first few cycles of high current
transients, as conventional electro-mechanical switchgear takes at least 120ms to
disconnect. During that time at least 6 cycles of high current transients with associated
torque pulsations have been endured. Each has the ability to cause damage to the
wound assemblies.
• It is the duty of the generating set installer to understand the operational and fault
clearing characteristics of the network to which a generating set is connected.
• When a current transient exceeds 4.5 times the value of the alternator rated full load
rms current, the generating set must be disconnected until system stability is restored.
Before re-connection, the protection and control systems of the generating set must be
verified as being within operational parameters.

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VIBRATION LEVELS
STAMFORD alternators are designed to withstand vibration levels encountered on generating
sets built to meet the requirements of ISO 8528-9. As described in the Owner’s Manual and
AGN 008.
• Within the frequency envelope of 2Hz -300Hz, the vibration levels imposed on the
alternator by the generating set equipment package must not exceed:
o Vibration Displacement (S rms): 0.32mm
o Vibration Velocity (V rms): 20mm/sec
o Vibration Acceleration (a rms): 13m/sec2

BEARINGS
A maintenance programme of bearing assessment must be in place to ensure reliable bearing
operation.
Alternators with re-greasable bearings are supplied with information labels, which advise the
user of grease type, re-lubrication frequency and quantity of grease to be used. The
instructions are described in the Owner’s Manual and must be followed. The grease used is a
high specification synthetic compound that must not be mixed with grease of a different
specification.

HUMIDITY
If the Relative Humidity (RH) in which the alternator is operating is expected to be >=70%,
then factory specified anti-condensation heaters must be installed. In these conditions, the
anti-condensation heaters must be energised when the alternator is in service, but not
operating, to keep the alternator windings above dewpoint.

OPERATING MANUAL
The customer supplied manual for the generating set equipment package, must incorporate
the STAMFORD® alternator’s Owner’s Manual, where fundamental information regarding ac
generator (alternator) care is provided.
The site operating procedures must include the necessary guidance and instructions to
ensure the prevailing site conditions are appropriately considered and the necessary
maintenance regime is being applied.

PRACTICAL GUIDANCE TO ON-SITE OPERATING CONDITIONS AND IMPACTS TO

ALTERNATORS - SUMMARY

This section has been developed as a practical guide for customers on site operations and
maintenance staff, to support an increase in awareness of the impact and management of

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operational conditions and the minimising impact on the operational life of STAMFORD and
AvK branded alternators of those site conditions.
The content was derived from Cummins Generator Technologies in-use Application Guidance
Notes, as contained on the STAMFORD / AvK web site:
https://www.stamford-avk.com and is an abridged version of the content of those AGN’s, to
support operational staff in managing site operating conditions.

Safety Notice:
No guidance is offered or implied with respect to required Health and Safety procedures,
processes and country/regional / international requirements. It is expected that all
persons working on site based equipment is permitted to do so, based on the installed
equipment owner’s approval and permission for working access.
Refer to site specific requirements and the authorised person / Senior Authorised
person, before any access to plant and equipment, or work / assessment activity is
started.
As a minimum, Cummins Employees must comply with Cummins Electrical Safety
Rules, or higher rules where they exist.

Alternator Operating Voltage and Frequency Range

Alternators utilize wound rotor and stator components to develop rotating electromagnetic
fields, induced in static wires to develop and AC output voltage. Main rotor windings, as the
name suggests, are rotated around a shaft common axis, and for example, for a 4 pole rotor,
under rotation passing a stationary point, the magnetic field can be identified as changing
polarities, in sequence, north, south, north, south, so that the speed of rotation, for instance
shaft speed rotating at 1500RPM, multiplied by the number of pole pairs, (In a 4 pole rotor that
is 2 pole pairs), then all divided by 60 seconds will define the electrical frequency in cycles per
second. Of course, in 3 phase alternators, the stator windings are distributed in such a way
that all three phases have conductors having a voltage induced in relative position.

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Main stator windings are the static wires
that are housed in the iron core, in slots,
and configured in a range of coil, group
and phase connections, which are
designed to optimise the available active
materials and develop a defined electrical
output.

Basic 4 Pole Alternator Rotor and Stator

Winding Representation

To achieve optimum performance from a winding design, the ideal situation is to operate the
alternator at the specified voltage and frequency (V & Hz), called out on the rating plate. If this
is done, the output KVA, at given power factor will always be optimized.

Excerpt from IEC60034-1:2010

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When looking at the international design standards common in rotating electrical machines for
rating, IEC 60034-1:2010, there is an easy graphical representation of operational frequency
and voltage envelopes, as shown on the previous page, around the nominal Voltage and
Frequency rating points (crossing points in the target for operation), with zones to identify the
variance of operation.

The closer the machine is operated to the centre crossing point of Voltage and Frequency, the
less impact may be seen on temperature that each wound component runs at for a continuous
load condition. If the alternator is operated away from the centre, there will be some impact to
either 1 or both main wound assemblies, resulting in higher peak temperatures, and a potential
reduction in operational life.

There are just two operating frequencies associated with power distribution in worldwide AC
grid networks, 50Hz and 60Hz.

There are many countries around the world that operate at different voltages. It is important to
ensure that a generating set, which is designed to operate at a given voltage and frequency.
Some designs of alternators can accommodate a wide range of system voltages, but some
are very limited. Always check the alternator rating plate to confirm how the machine will
operate.

It may be possible to reconfigure the stator winding to meet the power system requirements,
or alternatively, if not, it may be possible to utilize a de-rate factor to allow operation at
conditions less than optimal. Always ask and confirm the alternator voltage and frequency
rating capability to operate at a voltage level outside the designed bandwidth.

To cope with the wide variety of combinations of voltage and frequency used in different
national systems, every alternator in the STAMFORD and AvK ranges may have several
different winding designs.

Alternator Rating

Alternator ratings are specified in accordance with national and international Standards, IEC
60034-1 for alternators and (IEC 60034-22: AC generators for reciprocating internal
combustion (RIC) engine driven generating sets). There are two types of rating that are
specified, Basic Continuous Rating (BR) and Peak Continuous Rating (PR).

Basic Continuous Rating (BR)

This is a maximum continuous rating derived for continuous running duty. The alternator will
have a maximum continuous rating at which the machine may be operated for an unlimited
number of hours per year, while meeting the thermal operational temperatures laid down in
requirements of the appropriate standards.
This drives an assessment of thermal stress and therefore insulation system life (how long the
alternator is designed to operate for at the given rated continuous load before the insulation
fails).

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For industrial use alternators, three Base Continuous Rating levels are offered, based on
temperature rise limits and a standards ambient temperature of 40°C:
Class “H” (125°C/40°C) Class “F” (105°C/40°C) Class “B” (80°C/40°C)

Peak Continuous Rating (PR)

Peak continuous rating is also known as Standby Rating or Peak Standby Rating, and
represents the absolute maximum load rating which the alternator can be run at, but with the
recognition that the insulation life will be significantly reduced as the higher rating causes
higher operating temperatures in the windings, resulting in accelerated thermal degradation.
The increased rating from base continuous rating will reduce the lifetime of the alternator by a
factor of between 2 to 6 times.

There are variations on the two main ratings, which involve definitions of continuous and
discontinuous load factors, as generating set builders optimise cost effective solutions to meet
market needs. Some will also identify limited number of operating hours at that identified kVA
rating, to limit thermal degradation, especially for well-defined standby applications.

The following table summarises the rating definitions in ISO8528-3 and IEC 60034-1 for the
Alternator and ISO 8528-1 for the Generating Set:

Summary of various International Standards Ratings for Alternators and Generating Sets

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It is always suggested that the specific alternator Nameplate is checked to ensure the rating
and duty are clearly understood.

Overload

If an alternator is operated above its designed base continuous rating, the operating
temperatures will increase to a level that will degrade and so, shorten the life of, the wound
components of the insulation system.

For a fixed percentage overload, the rate at which the operating temperatures increase is a
product of the alternator’s Thermal Time Constant. This thermal time constant factor varies in
proportion to:

1. The physical mass of the wound components, which in turn affects the rate of thermal
rise. For example; larger alternators up to 300kVA cope better with overloads than
small alternators with outputs around 50kVA.

2. The percentage level of overload above the alternator’s designed Class ‘H’ rating.

3. The duration of the overload condition.

4. The operating temperature of the wound components just before the overload condition
begins.

5. The ambient temperature during the overload condition.

Ultimately, thermal overload should be avoided where at all possible. In all cases and as a
general practical rule of thumb, continuous overload above 110% of the alternator Nameplate,
applied for longer than 1 hour, will cause accelerated thermal degradation and bring about
earlier end of life condition. Also, be aware that the relationship of overload and thermal
degradation is not linear.

The rule of thumb for insulation design life is, the life of the insulation system is halved for
every 10 Degrees higher thermal operating condition.

This importantly applies for every condition of increasing thermal stress. If for instance the
ambient temperature is 10 Degrees hotter than the ambient for rating, say 50 Degrees at the
air inlet, and the alternator is run with restricted cooling air due to the generating set air filters
being partially clogged, and the alternator is running at 110% of rated load, there is every
likelihood that the thermal degradation can be accelerated, reducing the design life from say
40,000 Hours to less than say 5,000 Hours.

Example: with 3 thermal acceleration factors:

40K design life:
40K / 2 [10% overload] = 20K
20k / 2[10Deg increase in ambient temperature] = 10K

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10k / 2[ restricted air flow reduces effective cooling] = 5K

The result is total operational life reducing to around 0.8 years, (based on average 6K
per year) of life from the nominal 8 years.

The above illustration details only 3 of the many possible factors impacting thermal
insulation life of the alternator

Power Factor

Power factor is a way of identifying the electrical relationship between the active real power,
also known as working power (kWe), required to do the job, and the consumed apparent power
(kVA). The difference being due to the electrical characteristics of the electrical load applied
to the alternator.

In electrical engineering terms, the power factor of an a.c. power system is the ratio of the real
power (kWe) flowing to the load to the apparent power (kVA) in the electrical circuit.

The nature of the load in an a.c. circuit will determine if the current drawn is in phase or out of
phase with the generated voltage. The load again determines if that current waveform ‘leads’
the voltage waveform or ‘lags’ the voltage waveform. For normal industrial loads (e.g. motors)
the current will lag the voltage by some time interval or phase angle. The optimum situation is
where current and voltage are in phase. This makes the power factor unity (1.0) and hence the
real power (kW) the same as the product of voltage and current (kVA). Conventionally,
alternator kVA ratings are based on a lagging power factor of 0.8. In this case the current will
lag the voltage by an amount that causes the real power level supplied (kW) to fall below the
kVA level by a factor of 0.8 times.

Unity PF Lagging PF Leading PF

What Causes Power Factor?

Power factor basically is a measurement of the timing - phase angle difference - of the current
waveform relative to the voltage waveform. The idea being to identify how effectively the

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supplied power (kVA) is working in relation to the real work being done (kWe). The power is
being used more effectively when the power factor is closer to unity.

It is possible for a load to demand a current that is almost totally out of phase with the generated
voltage. Also, that current may be lagging the voltage (inductive or motor loads) or leading the
voltage (capacitive loads).

When operating in parallel, care must be taken to manage power factor to ensure the
generating set alternator is not overloaded.

When choosing to operate the generating set at power factors away from the range of 1.0
(Unity) to 0.8PF lagging, it is very easy to thermally overload the alternator by running a low
lagging PF, as even though only a small real power (kW) is demanded by the load, which is
well within the machines capability, damage can easily result if the load is a very low power
factor load demanding a very high kVA level, and so result in very high alternator phase
current.

Load Sharing

While the active power (kWe) sharing between generating sets during parallel operation is
governed by the engine control systems, the reactive power (kVAr) sharing is controlled by
the alternator’s control systems.

There are various recognised load sharing methods in the generator industry, such as
isochronous load sharing, cross-current compensation and quadrature droop load sharing.

Quadrature droop load sharing is the standard kVAr load sharing method utilised by Cummins
Generator Technologies. For AvK and STAMFORD alternators, quadrature droop load sharing
requires a Droop Current Transformer (CT) to be fitted on one of the alternator’s output phases.
For AvK and STAMFORD alternators fitted with digital Automatic Voltage Regulator’s (AVR),
the quadrature droop should be programmed on installation. For STAMFORD alternators fitted
with analogue AVRs, the CT secondary winding should be connected to the AVR droop S1 -
S2 inputs.

The current signal from the Droop CT secondary winding is converted to a voltage signal
across a burden resistor within the AVR. This voltage signal is then added vectorially to the

AGN 238 ISSUE A/12/20

AVR sensing voltage so that the AVR will be “tricked” to droop the voltage by adjusting the
excitation levels accordingly, in proportion to the levels of load current and power factor.

Example of AVR and Quadrature Droop CT Connection

It is important to have the droop CT on the same phase and the same AVR droop setting for
all paralleled alternators (usually 3% at 0.8pf) to ensure proportional kVAr sharing among the
Generating Sets.

Example of vectoral addition of droop signal to the AVR sensing voltage

Because the percentage ‘droop’ of the output voltage is related mainly to the reactive
component of the load current, the droop is negligible when the load current is at unity power
factor. For this reason, any attempt to check the operation of the ‘droop’ characteristic by
testing with a resistive load bank will not result in any observed ‘droop’ in the generating set’s
output voltage.

When considering setting the generating set alternator quadrature droop circuit, please refer
to the Owner’s Manual. It is vital that you understand all controls and settings before any
adjustment is made. It is very easy to trip a generating set when operating in parallel with only
very small adjustments, depending on the installed generating set protection settings.

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Cooling Air for an Alternator

Both open air ventilated alternators and enclosed alternators with cooling sub-systems, must
have a cooling system that operates at a certain temperature and volume of air through the
alternator, to cool the components to a satisfactory temperature so that alternator does not
overheat. The temperature that must be maintained is influenced by the air surrounding the
alternator. This is commonly referred to as ambient temperature.

An example of a Generating Set cooling system design.

Ambient Temperature
Ambient temperature can be defined as the temperature of the surrounding air at a particular
location. The internationally accepted standard value for industrial use alternators is 40°C.

The ambient temperature measured should be, in the case of an air-cooled machine such as
an AvK or STAMFORD alternator, the air inlet air temperature. This may be higher than the
surrounding air ambient temperature, due to the heat generated by the prime mover within the
confined space of an engine house.

It is essential that the total actual temperature does not exceed the limits set by the Nameplate
rating and ambient temperature identified. In some cases, especially marine machines, or for
special rating cases, ambient temperatures higher than 40°C, may be specified and allowed
for.

An industrial alternator operating in an ambient temperature greater than 40°C, must be de-
rated to ensure that total actual temperature does not exceed the specified maximum.

The converse of this is also true; that by reducing temperature a greater output can be obtained
from an alternator for the same actual temperature. This is permitted in most standards down
to an ambient of 30°C.

Airflow Through the Alternator

As a standard, industrial alternators are designed for use in a maximum ambient temperature
of 40°C, and altitude no higher than 1000 meters above sea level. (Air density affects cooling
capability of the air – the higher the altitude, the less dense the air is, so less dense air has
less cooling capability.)

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Where ambient temperatures in excess of 40°C and altitudes above 1000 meters exist, these
environmental operating conditions can be tolerated with reduced ratings. Refer to AGN 012
for further information.
The internal air flow is moved by a fan fixed on the machine shaft which is designed to create
a pressure drop which in turn cools the alternator rotor and stator windings. The air inlet is
located at the non-drive-end of the alternator while the air outlet is located at the drive-end of
the alternator as show in the following illustration. Cooling air flows into the alternator through
the air inlet at 40oC, cools the windings as it passes through the air gap (air path) and exit
through the air outlet at about 70oC.

Example of the air-cooled alternator

Airflow requirements
If the generating set is installed in a building or enclosure, efficient cooling will depend on
maintaining the condition of the cooling fan and air filters. There shall be no recirculating air in
the generating set room to maintain the ambient temperature entering the room. If the
operating environment differs from the values shown on the alternator nameplate, the rated
output must be adjusted.

Alternator Air Filters

There are two types of Air Inlet Filter used on AvK and STAMFORD alternators. The type of
filter design will be selected for specific environmental conditions, based on the customers
identified operating conditions, sized to meet those declared conditions, and specified on the
original alternator order confirmation. The two types are:
• Dry Dust Filter
• Moisture Filter

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Both types of filters are manufactured by companies specialising in air filtration systems and
each type of filter kit is a proprietary package from that company’s standard range of
appropriate products.

Environmental Conditions
When considering a proposed operational site with a contaminated atmosphere, careful
consideration must be given to the design and operational functionality of the generating set
housing, with special attention to air inlet and air outlet apertures. The next area of concern
must be the internal airflow management system in conjunction with the type of contamination
that will inevitably enter the generating set housing. Finally, the type of supplementary filter
required at point of entry to the alternator, the engine and its cooling system.

The decision-making process regarding the need to consider an abnormal site and associated
contaminated atmosphere must be a controlled function within the generating set
manufacturer’s commercial operation, where direct contact exists with the end user, their
needs and required duty for any proposed generating set to identify the following points for
sizing consideration
Requirements, i.e.
1. the type of contamination, particulate size
2. the medium of contamination, (carrier: air, moisture, water spray, etc)
3. The chemical composition (Acid/neutral/Alkoline)
4. The expected level of contamination (concentration of contamination verses carrier
volume / density)
It is very important that the generating set supplier and installer are fully aware of the risk they
place on the generator installation and equipment, to prevent operational problems occurring
related to site conditions.
Air inlet filters are constructed into a specially fitted filter framework at the factory. Each filter
assembly is designed specifically for a particular alternator frame size and should be fitted at
the factory during alternator manufacture.
It is strongly recommended that all alternators fitted with air inlet filters are specified to be
factory fitted with stator winding temperature detection devices, or differential pressure
switches, thereby providing an automatic control system that can be employed to ensure that
blocked air filters are detected before a winding overheats, with the risk of burn-out occurring.
Remember that maintenance of Air filters is vital to ensuring an adequate volume and
temperature of ambient cooling air is supplied to the alternator.
Also remember that seasons change, and the regime of inspection and clean / replacement
may also change, depending on the prevailing operational conditions.
As a rule of thumb, at commissioning, it is always wise to monitor air filters, so that it is possible
to track alternator changing operational conditions, over time, and then confirm filter change /
cleaning, when a tip up in alternator RTD temperatures or greater than 5 to 7oC, or an increase
to 30 to 40% blocked condition is reached on the differential pressure switch.

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IP Codes
IEC 60034-5:2000 describes the system for classifying the degrees of protection provided by
the enclosures of rotating electrical machines such as motors and alternators. The majority of
AvK and STAMFORD alternators are air-cooled, IC01 designed products with the air being
drawn through the alternator by an internal fan, which is fitted to the Drive End (DE) of the
alternator shaft.
The cooling airflow enters the alternator via the Non-Drive End (NDE), with the hot air being
expelled at the DE.
Each of the openings associated with the cooling-air path must be fitted with a screen and, on
occasion, an additional louver to comply with the relevant EU Directives for ac generators
(alternators); primarily 2006/42/EC Machinery Directive. The chosen design of screen and
louver will provide different levels of protection against the ingress of solid objects, plus the
harmful ingress of liquids.
The degree of enclosure protection provided is indicated by the International Protection or ‘IP’
Code where the code typically includes two numbers. The first number is associated with the
degree protection for persons, or limiting the size of solid objects that can enter the machine.
The second number is associated with liquid ingress protection, water being the most likely
liquid that the alternator may be exposed to.
The following tables provide definition of the numbers and additional letters that make up the
IP code:

IP Code First Numeral Indication (Particles)

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 IP Code Second Numeral Indication (Moisture)

A typical alternator intended for use in an industrial application has an IP code number of 23
(IP 23). The ‘2’ indicates that an object bigger than 12.5mm diameter, for example a finger,
cannot enter the alternator and touch anything either moving or electrically live. The ‘3’
indicates that the alternator’s ventilation openings are designed to provide protection from
falling liquids, for example rain water, which may be blown by the wind towards the alternator
at some 600 from the vertical.

IP Codes on STAMFORD Alternators

All STAMFORD alternators have a standard build with enclosure protection rated at IP23.
Where IP protection is fitted from original specified supply, the IP covers will have been allowed
for in terms of thermal impact to the alternator performance. It is normal during sizing, to allow
an allowance of around 5% rating reduction, to manage the additional difficulties of air flowing
through IP23 covers at each opening.
It is possible for larger airborne objects such as discarded work cloths, paper, cardboard, or
other substances to be sucked into the IP23 air inlet covers.
If this occurs, and is left without removing the contamination, the alternator may see some
additional cooling air starvation, and as a result, see an increased thermal condition, which will
increase winding operational temperatures, and accelerate thermal stress, reducing
operational life.

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Take care to complete regular maintenance checks to ensure that IP covers are clear of debris,
undamaged and remain in a good fitted condition.

Environmental Operating Conditions

There are technical considerations that must be initiated when using an alternator for
applications where the operational conditions are challenging.

Challenging Operating Temperatures

Winding Operating Temperatures:
• All low voltage alternators manufactured by Cummins Generator Technologies have
an insulation system based on Class H materials for a total temperature of 180oC.

• Once in service, the life expectancy of any wound component will be dependent upon
complex factors, with the operating temperature of that wound assembly being a
principal factor, because as the operating temperatures increase, the following
parameters are exponentially reduced. (as previously discussed in the Operational
Conditions section above)
Electrical Insulation systems evaluation data, such as completed for UL certification, suggests
that if the wound component is operated at 180oC for some 20,000 hours, the system will incur
a measurable level of ‘thermal degradation’, which in laboratory terms is described as a
reduction to a ‘half-life’ condition. This does not mean that the insulation system will fail at
40,000 hours, it is simply a laboratory ‘measure’ of the now degraded condition of the insulation
materials due to ‘thermal degradation’.
For comparison, UL advises that if a Class H insulation system is operated at a Class F (155oC)
rating, then the half-life increases to 120,000 hours and if operated at a Class B (120oC) rating,
then the half-life increases to 640,000 hours.
It must be pointed out that many factors affect the life expectancy of a wound assembly, and
whilst the operating temperature may well be the principal factor, other environmental and
operational factors come into play when considering impact to design operational life:
• Air borne contamination, which if allowed to come into contact with the surface of the
windings thereby promoting surface tracking, or initiating chemical erosion.

• Transiently Imposed vibration during transportation, or continuous vibration from the

prime-mover, which subsequently promote relative movement between phase to phase
or phase to earth insulation barriers.

• Voltage spikes or current surges generated by the connected load that challenge the
dielectric strength of the insulation system, which under extremely unstable conditions
(deviations from rated voltage and current conditions) the stresses may initiate a
rupture of the insulation barrier.

AGN 238 ISSUE A/19/20

The following table and notes are offered as a reference guide for the operating temperature
limits of a typical low voltage industrial alternator. The above recommendations should be
considered against the following tabled values, which are the Cummins Generator
Technologies recommended typical operating thermal limits, as measured by stator winding
embedded RTD’s.

Class F Alarm 145oC Class H Alarm 170oC

Class F Trip 165oC Class H Trip 190oC

The above values indicate the advised thermal limits for a typical industrial application where
the alternator is operating at fixed voltage level, totally under the control of its own AVR and is
supplying a connected load that does not exceed the rated nameplate values. The Nameplate
values being, voltage, current, power factor; and is a balanced three phase load with non-
distorting linear load characteristics. Also, the on-site conditions do not allow the temperature
at the air inlet to the alternator to exceed 40oC.

For further information or clarification on these Application Guidance

Notes, please contact STAMFORD / AvK Application Engineering

Email: applications@cummins.com

Application Guidance Notes are for information purposes only. Cummins Alternator Technologies reserves the right to change the contents of
Application Guidance Notes without notice and shall not be held responsible for any subsequent claims in relation to the content.

AGN 238 ISSUE A/20/20