REPORT NO.

05: NAME:
DC Generators and controls
INSTRUCTOR: DATE: 8 – 8 -2014 PAGE 1 OF 7
GRADE: ISSUE NO. 01

I. Generator components

1. Armature assembly - The armature

assembly of a rotary solenoid comprises of the
shaft, hub and armature plate. This is the
complete moving element of a rotary solenoid.

2. Field – frame assembly - The field frame

is also called the yoke, which is the foundation
or frame for the generator. The frame has two
functions: It completes the magnetic circuit between the poles and acts as a mechanical
support for the other part of the generator.

3. Brush Rigging - Brush rigging for a dynamoelectric machine such as an electric

cranking motor for cranking an internal combustion engine. A support carries a plurality of
radically extending brush holders each of which slid ably supports a brush.
REPORT NO. 05: NAME:
DC Generators and controls
INSTRUCTOR: DATE: 8 – 8 -2014 PAGE 2 OF 7
GRADE: ISSUE NO. 01

4. End frames - An end frame and stator

assembly for a dynamoelectric machine such
as an alternating current generator. The
assembly comprises a slotted stator core that
supports a stator winding, a rotor bearing and
a metallic heat dissipating insert that supports
the bearing.

5. Cooling features - The configuration of

water cooling in its simplest form is a three
typical main process parameters for water
cooling are these: a water inlet temperature of
30°C (assumption for stored water), water
discharge temperature of 80°C (limited by engine temperature), and required water flow
of 66 cubic meters per hour.

6. Name plate data - These plates describing the model name and manufacturer
usually also contain the rated output, but the rated output of a power station to the
electrical grid is usually less than the generator capacity because the components outside
the generator, but inside the power station, also use power, which detracts from the
amount that reaches the grid. Thus there is a distinction between component capacity and
facility capacity.
REPORT NO. 05: NAME:
DC Generators and controls
INSTRUCTOR: DATE: 8 – 8 -2014 PAGE 3 OF 7
GRADE: ISSUE NO. 01

II. Generator control

1. Principles of Voltage Regulation - A voltage regulator is designed to

automatically maintain a constant voltage level. A voltage regulator may be a simple
"feed-forward" design or may include negative feedback control loops. It may use an
electromechanical mechanism, or electronic components. Depending on the design, it may
be used to regulate one or more AC or DC voltages. Feedback voltage regulators operate
by comparing the actual output voltage to some fixed reference voltage. Any difference is
amplified and used to control the regulation element in such a way as to reduce the
voltage error.

2. Vibrator - Type Voltage Regulator - A voltage control used with some of the
simpler direct current generators. The voltage sensor is an electromagnetic relay whose
coil is connected across the generator output. The relay contacts are in the generator field
circuit. As soon as the generator output voltage reaches the value for which the voltage
regulator is set, the electromagnetic field in the relay pulls the contacts open. Field
current is reduced and the generator output voltage drops. As soon as the voltage is low
enough, the relay contacts close and field current again flows. The contacts vibrate open
and closed several hundred times a minute to hold the generator voltage within the
desired range.

3. Carbon - File Regulator - A carbon pile voltage regu1ator is ordinarily associated

with a generator for the purpose of controlling the voltage. The generator, such a carbon
pile regulator includes a carbon pile made up of a plurality of carbon discs and" which is
connected in series with the field of the generator. As the pressure on the carbon pile
varies, the strength of the field is correspondingly varied and the generator regulated.
REPORT NO. 05: NAME:
DC Generators and controls
INSTRUCTOR: DATE: 8 – 8 -2014 PAGE 4 OF 7
GRADE: ISSUE NO. 01

4. Equalizing Currents - Current that

circulates between two parallel-connected
compound generators to equalize their
output.

5. Current Limiter - Current limiting is the

practice in electrical or electronic circuits of
imposing an upper limit on the current that
may be delivered to a load with the purpose
of protecting the circuit generating or
transmitting the current from harmful effects
due to a short-circuit or similar problem in
the load.
REPORT NO. 05: NAME:
DC Generators and controls
INSTRUCTOR: DATE: 8 – 8 -2014 PAGE 5 OF 7
GRADE: ISSUE NO. 01

6. Two Unit Control Panel - a control panel is a set of displays that indicate the
measurement of various parameters like voltage, current and frequency, through gauges
and meters. These meters and gauges are set in a metallic body, usually corrosion proof,
to protect from the effect of rain or snow. The panel may be set up on the body of the
generator itself, which is usually the case with small generators. If they are mounted on
the generator, they typically have vibration proof pads that help isolate the control panel
from shocks. These units may also be shelf-mounted or wall-mounted next to the
generator, which is common inside an enclosure or internal application like a data center.
Control panels are usually fitted with buttons or switches that help to operate the
generator such as a switch-off button or turn-on key. The switches and gauges are
usually grouped on the basis of functionality. This makes the panel friendly and safe for
use since it minimizes the possibility of an operator accidentally selecting or executing the
wrong control. Imagine trying to shut down a vibrating generator with a spring loaded
lever in the middle of the night and you will appreciate why having a simple cut of switch
at the control panel makes sense.

7. Three Unit Control Panel - It is a system for adjusting the power output of
multiple generators at different power plants, in response to changes in the load. Since a
power grid requires that generation and load closely balance moment by moment,
frequent adjustments to the output of generators are necessary. The balance can be
judged by measuring the system frequency; if it is increasing, more power is being
generated than used, and all the machines in the system are accelerating. If the system
frequency is decreasing, more load is on the system than the instantaneous generation
can provide, and all generators are slowing down. Before the use of automatic generation
control, one generating unit in a system would be designated as the regulating unit and
would be manually adjusted to control the balance between generation and load to
maintain system frequency at the desired value. The remaining units would be controlled
with speed droop to proportion their share of the load according to their ratings. With
automatic systems, many units in a system can participate in regulation, reducing wear on
a single unit's controls and improving overall system efficiency, stability, and economy.
REPORT NO. 05: NAME:
DC Generators and controls
INSTRUCTOR: DATE: 8 – 8 -2014 PAGE 6 OF 7
GRADE: ISSUE NO. 01

III. Generator Inspection

1. Balancing Generator Load - The generator has two separate main power
producing circuits. These two circuits supply equal power to the receptacles shown when
the voltage selector switch is in the "120/240V" position. When two or more receptacles
are used; prevent overloading by dividing
the loads between the two power circuits.
2. Flashing the field - Generator field
flashing is required when generator
voltage does not build up and the
generating system does not have field
flash capability. This condition is usually
caused by insufficient residual magnetism
in the exciter and generator fields.
3. Generator Trouble Shooting -
Field testing and repairing can be
accomplished with basic tools and repair
parts which should include the following.
A quality multi meter capable of reading
less than one ohm and with a specific
diode testing function. Basic electrical
tools including cutters, soldering iron,
wire strapped crimper, terminals connectors, etc.
Repair parts such as diodes, fuses, bridge
rectifier, etc. Before electrical testing check for
proper engine speed/hertz adjustment. Low
engine speed will cause low AC voltage output,
high engine speed high AC output. Refer to
WESTERBEKE'S operators manual or service
manual for engine speed/hertz adjustment or for
other possible engine related problems.
4. Inspection - is, most generally, an organized
examination or formal evaluation exercise. In
engineering activities inspection involves the
measurements, tests, and gauges applied to
REPORT NO. 05: NAME:
DC Generators and controls
INSTRUCTOR: DATE: 8 – 8 -2014 PAGE 7 OF 7
GRADE: ISSUE NO. 01

certain characteristics in regard to an object or activity. The results are usually compared
to specified requirements and standards for determining whether the item or activity is in
line with these targets. Inspections are usually non-destructive.